Coating compositions comprising silyl blocked components, coatings, coated substrates and methods related thereto

ABSTRACT

Coating compositions formed from at least one hydroxyl functional non-vinyl material comprising at least one alcoholic hydroxyl group blocked with a hydrolyzable silyl group, and at least one curing agent are provided by the present invention. Another embodiment of the present invention is directed to a coating composition formed from components comprising at least one carbamate functional material comprising at least one carbamate group blocked with a hydrolyzable silyl group, and at least one curing agent. Another embodiment of the present invention is directed to a coating composition formed from components comprising at least one carboxyl functional material comprising at least one carboxyl group blocked with a hydrolyzable silyl group, and at least one curing agent. Another embodiment of the present invention is directed to a coating composition formed from components comprising at least one amide functional material comprising at least one amide blocked with a hydrolyzable silyl group, and at least one curing agent. Other embodiments of the present invention are directed to substrates coated with the aforementioned cured compositions. Also provided are multi-component composite coatings which include a cured basecoat deposited from a pigmented coating composition and a cured topcoat deposited from a topcoating composition. The multi-component composite coatings of the invention provide highly scratch resistant color-plus-clearcoatings. Further embodiments of the present invention are directed to methods for improving scratch resistance of a substrate.

This is a division of application Ser. No. 09/629,421, filed Jul. 31,2000, now U.S. Pat. No. 6,635,341, which is hereby incorporated byreference.

FIELD OF THE INVENTION

Certain embodiments of the present invention generally are directed tocoating compositions formed from at least one hydroxyl functionalnon-vinyl material comprising at least one alcoholic hydroxyl groupblocked with a hydrolyzable silyl group, and at least one curing agent.Other embodiments of the present invention are directed to coatingcompositions formed from at least one hydroxyl functional materialcomprising at least one alcoholic hydroxyl group blocked with ahydrolyzable silyl group, and at least one curing agent, in which thehydroxyl functional material has a polydispersity of less than 2.Further embodiments are directed to coating compositions formed from atleast one hydroxyl functional non-vinyl material comprising at least onealcoholic hydroxyl group blocked with a hydrolyzable silyl group, and atleast one curing agent, in which the hydroxyl functional material hasless than 5 hydroxyl functional groups. Still other embodiments aredirected to coating compositions formed from at least one hydroxylfunctional non-vinyl material comprising at least one alcoholic hydroxylgroup blocked with a hydrolyzable silyl group, and at least one curingagent present in an amount of at least 10 weight percent on a basis oftotal resin solids of the components of the coating composition. Furtherembodiments of the present invention are directed to coatingcompositions formed from components comprising at least one carbamatefunctional material comprising at least one carbamate group blocked witha hydrolyzable silyl group, and at least one curing agent. Still furtherembodiments are directed to coating compositions formed from componentscomprising at least one carboxyl functional non-vinyl materialcomprising at least one carboxyl group blocked with a hydrolyzable silylgroup, and at least one curing agent. Other embodiments are directed tocoating compositions formed from components comprising at least oneamide functional material comprising at least one amide group blockedwith a hydrolyzable silyl group, and at least one curing agent.

Embodiments of the present invention also are directed to cured coatingsformed from any of the aforementioned coating compositions. Otherembodiments of the present invention are directed to substrates coatedwith any of the aforementioned coating compositions. Further embodimentsof the present invention are directed to methods for improving scratchresistance of a substrate. It will be apparent to one of ordinary skillin the art that specific embodiments of the present invention may bedirected to some or all of these aspects of the present invention aswell as other desirable aspects.

BACKGROUND OF THE INVENTION

Over the past decade, there has been a concerted effort to reduceatmospheric pollution caused by volatile solvents which are emittedduring the painting process. However, it is often difficult to achievehigh quality, smooth coating finishes, such as are required in theindustrial and automotive industry, without using organic solvents whichcontribute greatly to flow and leveling of a coating. In addition toachieving near-flawless appearance, such coatings must be durable andabrasion resistant, yet economical and easy to apply.

The use of conventional thermally curable thermosetting resins forcoating compositions can be undesirable because of the necessity forthinning the resins with solvents to provide easy application tosubstrates. The use of solvents is undesirable for cost andenvironmental reasons because the solvents must be removed from thecoating composition during cure.

I. Azuma et al., “Acrylic Oligomer for High Solid Automotive Top CoatingSystem Having Excellent Acid Resistance”, Progress in Organic Coatings32 (1997) 1–7, disclose acrylic oligomers containing siloxy groupssynthesized using trimethylsiloxyethyl methacrylate, which have lowerpolarity and lower viscosity than acrylic oligomers comprising unblockedhydroxyl groups and are useful for formulating high solids automotivetop coatings.

U.S. Pat. No. 6,045,870 discloses an organic solvent-based heat-curablecoating composition comprising: (A) a carboxyl-containing vinyl polymeror carboxyl-containing polyester compound having an acid value of 50 to500 mg KOH/g wherein 20 mol % or more of the carboxyl groups aresilylated; (B) at least one epoxide selected from (B-1) an epoxy-,hydroxyl- and hydrolyzable alkoxysilyl-containing vinyl polymer, (B-2)the vinyl polymer (B-1) wherein 20 mol % or more of the hydroxyl groupsare silylated hydroxyl groups, and (B-3) an epoxy compound having anumber average molecular weight less than 1,000; (C) a crosslinkedparticulate polymer, and optionally (D) a reactive organopolysiloxane,the composition having a solid content of 65 weight % or more and havinggood acid and scratch resistance, low temperature curability, storagestability and recoat adhesion.

Color-plus-clearcoating systems involving the application of a coloredor pigmented basecoat to a substrate followed by application of atransparent or clearcoat over the basecoat have become increasinglypopular as original finishes for a number of consumer productsincluding, for example automotive vehicles. The color-plus-clearcoatingsystems have outstanding appearance properties such as gloss anddistinctness of image, due in large part to the clearcoat. Suchcolor-plus-clearcoating systems have become popular for use withautomotive vehicles, aerospace applications, floor coverings such asceramic tiles and wood flooring, packaging coatings and the like.

Topcoat film-forming compositions, particularly those used to form thetransparent clearcoat in color-plus-clearcoating systems for automotiveand industrial applications, are subject to defects that occur duringthe assembly process as well as damage from numerous environmentalelements. Such defects during the assembly process include paint defectsin the application or curing of the basecoat or the clearcoat. Damagingenvironmental elements include acidic precipitation, exposure toultraviolet radiation from sunlight, high relative humidity and hightemperatures, defects due to contact with objects causing scratching ofthe coated surface, and defects due to impact with small, hard objectsresulting in chipping of the coating surface.

Typically, a harder more highly crosslinked film may exhibit improvedscratch resistance, but it is less flexible and much more susceptible tochipping and/or thermal cracking due to embrittlement of the filmresulting from a high crosslink density. A softer, less crosslinkedfilm, while not prone to chipping or thermal cracking, is susceptible toscratching, waterspotting, and acid etch due to a low crosslink densityof the cured film.

Further, elastomeric automotive parts and accessories, for exampleelastomeric bumpers and hoods, are typically coated “off site” andshipped to automobile assembly plants. The coating compositions appliedto such elastomeric substrates are typically formulated to be veryflexible so the coating can bend or flex with the substrate withoutcracking. To achieve the requisite flexibility, coating compositions foruse on elastomeric substrates often are formulated to produce coatingswith lower crosslink densities or to include flexibilizing adjuvantswhich act to lower the overall film glass transition temperature (Tg).While acceptable flexibility properties can be achieved with theseformulating techniques, they also can result in softer films that aresusceptible to scratching. Consequently, great expense and care must betaken to package the coated parts to prevent scratching of the coatedsurfaces during shipping to automobile assembly plants.

Despite recent improvements in color-plus-clearcoating systems, thereremains a need in the automotive coatings art for topcoats having lowvolatile organic content (“VOC”) and which are capable of beingformulated into high solids coating compositions. Other desirableattributes of the coating include good recoat adhesion and good scratchresistance without embrittlement of the film. Moreover, it would beadvantageous to provide topcoats for elastomeric substrates utilizablein the industrial and automotive industries which are both flexible andresistant to scratching.

SUMMARY OF THE INVENTION

In one embodiment, the present invention is directed to a coatingcomposition formed from components comprising (a) at least one hydroxylfunctional non-vinyl material comprising at least one alcoholic hydroxylgroup blocked with a hydrolyzable silyl group, and (b) at least onecuring agent reactive with the at least one hydroxyl functionalnon-vinyl material (a).

In other embodiments, the present invention is directed to coatingcompositions formed from components comprising (a) at least one hydroxylfunctional material comprising at least one hydroxyl group blocked witha hydrolyzable silyl group, the hydroxyl functional material having apolydispersity of less than 2, of less than 1.5, or of less than 1.2,and (b) at least one curing agent reactive with the at least onehydroxyl functional material (a).

In another embodiment, the present invention is directed to a coatingcomposition formed from components comprising (a) at least one hydroxylfunctional material comprising at least one hydroxyl group blocked witha hydrolyzable silyl group, the hydroxyl functional material having lessthan 5 hydroxyl functional groups, and (b) at least one curing agentreactive with the at least one hydroxyl functional material (a).

In another embodiment, the present invention is directed to a coatingcomposition formed from components comprising: (a) at least one hydroxylfunctional material comprising at least one hydroxyl group blocked witha hydrolyzable silyl group, and (b) at least 10 weight percent on abasis of total resin solids of the components which form the coatingcomposition of at least one curing agent reactive with the at least onehydroxyl functional material (a).

In another embodiment, the present invention is directed to a coatingcomposition formed from components comprising: (a) at least onecarbamate functional material comprising at least one carbamate groupblocked with a hydrolyzable silyl group, and (b) at least one curingagent reactive with the at least one carbamate functional material (a).

In another embodiment, the present invention is directed to a coatingcomposition formed from components comprising (a) at least one carboxylfunctional non-vinyl material comprising at least one carboxyl groupblocked with a hydrolyzable silyl group, and (b) at least one curingagent reactive with the at least one carboxyl functional non-vinylmaterial (a).

In another embodiment, the present invention is directed to a coatingcomposition formed from components comprising (a) at least one amidefunctional material comprising at least one amide group blocked with ahydrolyzable silyl group, and (b) at least one curing agent reactivewith at least one amide functional material (a).

Additionally, a coated substrate is disclosed to be within the scope ofthe present invention which comprises a substrate and a curedcomposition coated over at least a portion of the substrate, the curedcomposition being formed from any of the foregoing coating compositionsaccording to the present invention. The present invention also providesa method of coating a substrate which comprises forming over at least aportion of the substrate a cured composition, the cured compositionbeing any of the foregoing compositions according to the presentinvention. Coated automotive substrates also are disclosed to be withinthe present invention which comprise an automotive substrate which iscoated, at least in part, by any of the foregoing compositions accordingto the present invention. The present invention also provides methods ofmaking coated automotive substrates comprising obtaining an automotivesubstrate and forming over at least a portion of the automotivesubstrate any of the foregoing compositions according to the presentinvention.

Also provided are multi-component composite coating compositions whichcomprise a basecoat deposited from a pigmented coating composition, andany one of the foregoing compositions according to the present inventionformed as a topcoat over the basecoat. The present invention alsoprovides methods for making multi-component composite coatingcompositions comprising: (a) applying a pigmented composition to asubstrate to form a basecoat; and (b) applying any one of the foregoingcoating compositions as a topcoating composition over at least a portionof the basecoat, and (c) curing the topcoating composition to form anyof the foregoing cured compositions according to the present invention.

Additionally provided are monocoat coating compositions which comprise apigment added to any one of the foregoing compositions according to thepresent invention.

Methods of improving the scratch resistance of a polymeric substrate orpolymeric coating which comprise forming on the polymeric substrate orpolymeric coating any of the foregoing coating compositions according tothe present invention also are provided in another embodiment of thepresent invention. The present invention also provides methods forretaining the gloss of a polymeric substrate or polymeric coating overtime which comprises forming over at least a portion of the polymericsubstrate or polymeric coating any of the foregoing coating compositionsaccording to the present invention. Also provided are methods forrevitalizing the gloss of a polymeric substrate or polymeric coatingcomprising forming over at least a portion of the polymeric substrate orpolymeric coating any of the foregoing coating compositions according tothe present invention.

Other than in the operating examples, or where otherwise indicated, allnumbers expressing quantities of ingredients, reaction conditions, andso forth used in the specification and claims are to be understood asbeing modified in all instances by the term “about.” Accordingly, unlessindicated to the contrary, the numerical parameters set forth in thefollowing specification and attached claims are approximations that mayvary depending upon the desired properties sought to be obtained by thepresent invention. At the very least, and not as an attempt to limit theapplication of the doctrine of equivalents to the scope of the claims,each numerical parameter should at least be construed in light of thenumber of reported significant digits and by applying ordinary roundingtechniques.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the invention are approximations, the numericalvalues set forth in the specific examples are reported as precisely aspossible. Any numerical value, however, inherently contain certainerrors necessarily resulting from the standard deviation found in theirrespective testing measurements.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In one embodiment, the present invention is directed to coatingcompositions formed from components comprising at least one hydroxylfunctional non-vinyl material comprising at least one alcoholic hydroxylgroup blocked with a hydrolyzable silyl group, and at least one curingagent reactive with the alcoholic hydroxyl group of the at least onehydroxyl functional non-vinyl material (a). As used herein, “material”can be a compound, monomer, or polymer. Additionally, as used herein,the term “polymer” in meant to encompass oligomer, and includes withoutlimitation both homopolymers and copolymers.

Hydrolysis of the silyl group regenerates the reactive functional groupon the material which is then available for further reaction with the atleast one curing agent. During formation of the coating composition,blocking of the at least one hydroxyl group with the hydrolyzable silylgroup(s) can lower the viscosity of the coating composition to permithigher solids, lower VOC coating compositions to be prepared. In oneembodiment, the VOC of coating compositions prepared according to thepresent invention are less than 4 lbs/gallon, and can be less than 3.6lbs/gallon. The VOC of the coating compositions can be determined, forexample, by ASTM Method 24, which is incorporated herein by reference.

In one embodiment, the hydrolyzable silyl groups can have the followingstructure (IX):

wherein each R₁, R₂ and R₃, which may be identical or different,represents an alkyl group having from 1 to 18 carbon atoms, a phenylgroup or an allyl group.

Non-limiting examples of suitable compounds which can be reacted withthe alcoholic hydroxyl group to form the silyl group comprisehexamethyldisilazane, trimethylchlorosilane, trimethylsilyldiethylamine,t-butyl dimethylsilyl chloride, diphenyl methylsilyl chloride,hexamethyl disilylazide, hexamethyl disiloxane, trimethylsilyl triflate,hexamethyldisilyl acetamide, N,N′-bis[trimethylsilyl]-urea,hexamethyldisiloxane, ketene methyl trialkylsilyl acetals, triethylsilylperchlorate, allylsilanes and mixtures of any of the foregoing.

Further examples of suitable compounds for silylation reactions, andsuitable reaction conditions and reagents for trimethylsilylationreactions are discussed in the Example below and in T. Greene et al.,Protective Groups in Organic Synthesis, (2d. ed. 1991) at pages 68–86and 261–263, which are incorporated herein by reference.

In one embodiment, at least 1 mole percent of the alcoholic hydroxylgroups of the at least one hydroxyl functional non-vinyl material areblocked with hydrolyzable silyl groups. In another embodiment, at least25 mole percent of the alcoholic hydroxyl groups of the at least onehydroxyl functional non-vinyl material are blocked with hydrolyzablesilyl groups, while in yet another embodiment, at least 33 mole percentof the alcoholic hydroxyl groups of the at least one hydroxyl functionalnon-vinyl material are blocked with hydrolyzable silyl groups. Inanother embodiment, substantially all of the alcoholic hydroxyl groupsof the at least one hydroxyl functional non-vinyl material are blockedwith hydrolyzable silyl groups. As used herein, “substantially all ofthe alcoholic hydroxyl groups” means greater than 90%, and can meangreater than 95% of the alcoholic hydroxyl groups. The percentage ofblocked alcoholic hydroxyl groups may include any percentage within therange of recited values, inclusive of the recited values.

In one embodiment, the at least one hydroxyl functional non-vinylmaterial can have a hydroxyl equivalent weight, prior to silylation, ofat least 31 mg KOH per gram of the at least one hydroxyl functionalnon-vinyl material. In other embodiments, the at least one hydroxylfunctional non-vinyl material generally have a hydroxyl equivalentweight, prior to silylation, of less than 2000 mg KOH per gram, can havea hydroxyl equivalent weight, prior to silylation, of less than 1000 mgKOH per gram, and typically have a hydroxyl equivalent weight of lessthan 400 mg KOH of at least one hydroxyl functional non-vinyl material.The hydroxyl equivalent weight may range between any combination ofthese values inclusive of the recited values.

In one embodiment, the at least one hydroxyl functional non-vinylmaterial has less than 5 alcoholic hydroxyl functional groups, inanother embodiment, the material has less than or equal to 4 alcoholichydroxyl functional groups, and in yet another embodiment, 3 alcoholichydroxyl groups. As used herein, “alcoholic hydroxyl group” means ahydroxyl group which is attached to a carbon which is not part of acarbonyl group, i.e., is not part of a carboxyl group.

The at least one hydroxyl functional non-vinyl material backbone can bea compound which comprises at least one linkage selected from an esterlinkage, a urethane linkage, a urea linkage, an amide linkage, asiloxane linkage, and an ether linkage, or a polymer comprising at leastone such linkage, for example polyester, polyurethane, polyether,polyurea, polyamide, polysiloxane, and copolymers thereof. The at leastone hydroxyl functional material is a non-vinyl material. As usedherein, a “non-vinyl material” refers to any material which is notformed by free radical polymerization of monomers containing vinylfunctional groups. A used herein, “vinyl functional group” refers to agroup having the formula CH₂═C<. In one embodiment, the at least onehydroxyl functional non-vinyl material is a hydroxyl functionalpolyester.

In one embodiment, the at least hydroxyl functional non-vinyl materialis formed from components comprising (a) at least one half-ester formedfrom components comprising (i) at least one polyol and (ii) at least oneanhydride, and (b) at least one epoxy functional material or at leastone aliphatic diol.

Suitable compounds and polymers comprising ester groups and at least onealcoholic hydroxyl group include half-esters formed from reacting atleast one polyol with at least one anhydride such as 1,2-anhydrides. Thehalf-esters are typically used because they are of relatively lowmolecular weight and are quite reactive with epoxy functionality.

The half-ester may be obtained by reaction between a polyol and a1,2-anhydride under conditions sufficient to ring open the anhydrideforming the half-ester with substantially no polyesterificationoccurring. Such reaction products are of relatively low molecular weightwith narrow molecular weight distributions and low viscosity. By“substantially no polyesterification occurring” means that the carboxylgroups formed by the reaction of the anhydride are not furtheresterified by the polyol in a recurring manner. This means thatgenerally less than 10, and typically less than 5 percent by weight ofhigh molecular weight polyester is formed.

The 12-anhydride and polyol generally are mixed together and thereaction is conducted in the presence of an inert atmosphere such asnitrogen and a solvent such as a ketone or aromatic hydrocarbon todissolve the solid ingredients and/or lower the viscosity of thereaction mixture.

For the desired ring opening reaction and half-ester formation, a1,2-dicarboxylic anhydride can be used. Reaction of a polyol with acarboxylic acid instead of an anhydride would require esterification bycondensation and elimination water would have to be removed bydistillation. Under these conditions, this would promote undesiredpolyesterification. Also, the reaction temperature is generally low,i.e., less than 135° C. and can range from 70° C. to 135° C. The time ofreaction can vary somewhat depending upon the temperature of reaction,and generally ranges from 10 minutes to 24 hours.

The equivalent ratio of the at least one anhydride to the hydroxyl onthe at least one polyol may be at least 0.8:1 (the anhydride beingconsidered monofunctional) to obtain maximum conversion to the desiredhalf-ester.

Ratios less than 0.8:1 can be used but such ratios result in increasedformation of lower functionality half-esters.

Among the polyols which can be used are simple polyols, that is, thosecontaining from 2 to 20 carbon atoms, as well as polymeric polyols suchas polyester polyols, polyurethane polyols, and acrylic polyols.

Among the simple polyols are diols, triols, tetrols and mixturesthereof. Examples of the polyols include those containing from 2 to 10carbon atoms such as aliphatic polyols. Specific examples include butare not limited to the following compositions: di-trimethylolpropane(bis(2,2-dimethylol)dibutylether), pentaerythritol,1,2,3,4-butanetetrol, sorbitol, trimethylolpropane, trimethylolethane,1,2,6-hexanetriol, glycerine, trishydroxyethyl isocyanurate, dimethylolpropionic acid, 1,2,4-butanetriol, TMP/epsilon-caprolactone triols,ethylene glycol, 1,2-propanediol, 1,3-propanediol, 1,4-butanediol,1,5-pentanediol, 1,6-hexanediol, 2-ethyl-1,3-hexanediol, neopentylglycol, diethylene glycol, dipropylene glycol,1,4-cyclohexanedimethanol, and 2,2,4-trimethylpentane-1,3-diol. In oneembodiment, the at least one polyol is trimethylolpropane.

With regard to oligomeric polyols, suitable polyols are polyols madefrom reaction of diacids with diols, triols and/or tetrols, such astrimethylol propane/cyclohexane diacid and trimethylol propane/adipicacid.

With regard to polymeric polyols, the polyester polyols are prepared byesterification of an organic polycarboxylic acid or anhydride thereofwith organic polyols and/or an epoxide. Usually, the polycarboxylicacids and polyols are aliphatic or aromatic dibasic acids or anhydridesand diols.

The polyols which are usually employed in making the polyester includetrimethylol propane, di-trimethylol propane, alkylene glycols such asethylene glycol, neopentyl glycol and other glycols such as hydrogenatedbisphenol A, cyclohexanediol, cyclohexanedimethanol, the reactionproducts of lactones and diols, for example, the reaction product ofepsilon-caprolactone and ethylene glycol, hydroxy-alkylated bisphenols,polyester glycols for example poly(oxytetramethylene)glycol, and thelike.

Useful anhydrides include aliphatic, cycloaliphatic, olefinic,cycloolefinic and aromatic anhydrides. Substituted aliphatic andaromatic anhydrides also are useful provided the substituents do notadversely affect the reactivity of the anhydride or the properties ofthe resultant polyester. Examples of substituents include chloro, alkyland alkoxy. Examples of anhydrides include succinic anhydride,methylsuccinic anhydride, dodecenyl succinic anhydride,octadecenylsuccinic anhydride, phthalic anhydride, tetrahydrophthalicanhydride, methyltetrahydrophthalic anhydride, hexahydrophthalicanhydride, alkyl hexahydrophthalic anhydrides such asmethylhexahydrophthalic anhydride (preferred), tetrachlorophthalicanhydride, endomethylene tetrahydrophthalic anhydride, chlorendicanhydride, itaconic anhydride, citraconic anhydride, and maleicanhydride.

Besides the polyester polyols formed from polybasic acids and polyols,polylactone-type polyesters also can be employed. These products areformed from the reaction of a lactone such as epsilon-caprolactone and apolyol such as ethylene glycol, diethylene glycol andtrimethylolpropane.

Besides polyester polyols, polyurethane polyols such aspolyester-urethane polyols which are formed from reacting an organicpolyisocyanate with a polyester polyol such as those described above canbe used. The organic polyisocyanate is reacted with a polyol so that theOH/NCO equivalent ratio is greater than 1:1 so that the resultantproduct contains free hydroxyl groups. The organic polyisocyanate whichis used in preparing the polyurethane polyols can be an aliphatic oraromatic polyisocyanate or a mixture. Diisocyanates are generally used,although higher polyisocyanates such as triisocyanates can be also used,but they do result in higher viscosities.

Examples of suitable diisocyanates are 4,4′-diphenylmethanediisocyanate, 1,4-tetramethylene diisocyanate, isophorone diisocyanateand 4,4′-methylenebis(cyclohexyl isocyanate). Examples of suitablehigher functionality polyisocyanates are polymethylene polyphenolisocyanates.

At least a portion or all of the acid functional groups can be reactedwith at least one epoxy functional material and/or at least onealiphatic diol to provide alcoholic hydroxyl groups for silylation.

Useful epoxy functional materials include epoxy functional monomers suchas glycidyl methacrylate, ethylene oxide, butylene oxide, propyleneoxide (preferred), cyclohexene oxide, glycidyl ethers such as phenylglycidyl ether, n-butyl glycidyl ether, cresyl glycidyl ether, isopropylglycidyl ether, glycidyl esters such as glycidyl versatate, for exampleCARDURA E available from Shell Chemical Co., and mixtures of any of theforegoing. Other useful epoxy functional materials include polymerscomprising at least two epoxide or oxirane groups per molecule. Thesematerials often are referred to as di- or polyepoxides.

Suitable epoxy-functional polymers can be saturated or unsaturated,cyclic or acyclic, aliphatic, alicyclic, aromatic or heterocyclic. Theepoxy-functional polymers can have pendant or terminal hydroxyl groups,if desired. They can contain substituents such as halogen, hydroxyl, andether groups. A useful class of these materials include polyepoxidesobtained by reacting an epihalohydrin (such as epichlorohydrin orepibromohydrin) with a di- or polyhydric alcohol in the presence of analkali. Suitable polyhydric alcohols include polyphenols such asresorcinol, catechol, hydroquinone, bis(4-hydroxyphenyl)-2,2-propane,i.e., bisphenol A, bis(4-hydroxyphenyl)-1,1-isobutane,4,4-dihydroxybenzophenone, bis(4-hydroxyphenol)-1,1-ethane,bis(2-hydroxyphenyl)-methane and 1,5-hydroxynaphthalene.

Examples of useful polyepoxides include diglycidyl ethers of bisphenolA, such as EPON® 828 epoxy resin which is commercially available fromShell Chemical Company. Other useful polyepoxides include polyglycidylethers of polyhydric alcohols, polyglycidyl esters of polycarboxylicacids, polyepoxides that are derived from the epoxidation of anolefinically unsaturated alicyclic compound, polyepoxides containingoxyalkylene groups in the epoxy molecule, epoxy novolac resins, andpolyepoxides that are partially defunctionalized by carboxylic acids,alcohol, water, phenols, mercaptans or other active hydrogen-containingcompounds to give hydroxyl-containing polymers.

The equivalent ratio of epoxy groups to acid groups on the estergenerally ranges from 0.1:1 to 2:1, can range from 0.5:1 to 1:1, andtypically ranges from 0.8:1 to 1:1.

Useful aliphatic diols include diols containing a primary hydroxyl suchas 1,2-propanediol, 1,3-propanediol, 1,2-butanediol, 1,3-butanediol,1,2-pentanediol, 1,4-pentanediol, 1,2-hexanediol, 1,5-hexanediol,2-ethyl-1,3-hexanediol, diethylene glycol, dipropylene glycol,1,4-cyclohexanedimethanol, 2,2,4-trimethyl-1,3-pentanediol, and3,3-dimethyl-1,2-butanediol.

In one embodiment, the present invention is directed to coatingcompositions as previously described, wherein the at least one hydroxylfunctional non-vinyl material comprises at least one compound having thefollowing structure (X):

For example, the silylated compound can be the reaction product oftrimethylolpropane, methylhexahydrophthalic anhydride, propylene oxide,and hexamethyl disylizid reacted at a ratio of 1:3:3:3.

Other useful hydroxyl functional non-vinyl materials includepolyurethane polymers containing terminal hydroxyl groups. Thepolyurethane polyols which can be used are those prepared by reactingpolyols including polymeric polyols with polyisocyanates. Non-limitingexamples of suitable hydroxy functional polyurethanes include thereaction product of DESMODUR 3300, available from Bayer USA, with anexcess of a suitable glycol, such as ethylene glycol or propyleneglycol.

Polyureas containing terminal hydroxyl groups which also can be used canbe those prepared by reacting polyamines with polyisocyanates.Non-limiting examples of suitable hydroxy functional polyureas includethe reaction product of an excess of DESMODUR 3300, available from BayerUSA, with ethylene diamine, followed by a reaction of the resultantproduct with an excess of a suitable glycol, such as ethylene glycol orpropylene glycol.

Nonlimiting examples of suitable polyether polyols include polyalkyleneether polyols such as those having the following structural formulas(VII) or (VIII):

wherein the substituent group R represents hydrogen or a lower alkylgroup of 1 to 5 carbon atoms including mixed substituents, n has a valueranging from 2 to 6, and m has a value ranging from 8 to 100 or higher.Nonlimiting examples of polyalkylene ether polyols includepoly(oxytetramethylene)glycols, poly(oxytetraethylene)glycols,poly(oxy-1,2-propylene)glycols, and poly(oxy-1,2-butylene)glycols.

Also useful can be polyether polyols formed from oxyalkylation ofvarious polyols, for example but not limited to, glycols such asethylene glycol, 1,6-hexanediol, Bisphenol A, and the like, or otherhigher polyols such as trimethylolpropane, pentaerythritol, and thelike. Polyols of higher functionality which can be utilized as indicatedcan be made, for instance, by oxyalkylation of compounds such as sucroseor sorbitol. One oxyalkylation method that can be used is reaction of apolyol with an alkylene oxide, including but not limited to, propyleneor ethylene oxide, in the presence of an acidic or basic catalyst.Specific, nonlimiting examples of polyethers include those sold underthe names TERATHANE and TERACOL, available from E. I. duPont de Nemoursand Co., Inc.

Suitable hydroxyl functional polyamides can be produced by reacting adiamine with an excess of a dicarboxylic acid, followed by reacting theresulting acid functional polyamide with excess glycol.

In one embodiment, the at least one hydroxyl functional non-vinylmaterial has a polydispersity of less than 2, while in anotherembodiment, the material has a polydispersity of less than 1.5, and inyet another embodiment, a polydispersity of less than 1.2.Polydispersity is the ratio of the weight average molecular weight tothe number average molecular weight of the hydroxyl functional non-vinylmaterial. G. Odian, Principles of Polymerization, (3d Ed. 1991) pp.19–24, which is incorporated herein by reference. Weight averagemolecular weight and number average molecular weight are determined bygel permeation chromatography using polystyrene as a standard.

In an alternative embodiment, silyl groups can be used to blockcarbamate functional groups of carbamate functional materials. Carbamatefunctional groups can be introduced into the at least one hydroxylfunctional non-vinyl material discussed above by reacting apolyisocyanate with a polyester having hydroxyl functionality andcontaining pendant carbamate groups. Alternatively, the carbamatefunctional groups can be incorporated into the at least one hydroxylfunctional non-vinyl material by reacting the at least one hydroxylfunctional non-vinyl material with a low molecular weight carbamatefunctional material via a “transcarbamoylation” process. The lowmolecular weight carbamate functional material, which can be derivedfrom an alcohol or glycol ether, can react with free hydroxyl groups ofa polyol, that is, material comprising an average of two or morehydroxyl groups per molecule, yielding a carbamate functional materialand the original alcohol or glycol ether. For example, the polyurethanecan be prepared by reacting a polyisocyanate with a polyester polyol anda hydroxyalkyl carbamate or isocyanic acid as separate reactants.Nonlimiting examples of suitable polyisocyanates include aromaticisocyanates, (such as 4,4′-diphenylmethane diisocyanate, 1,3-phenylenediisocyanate, and toluene diisocyanate), and aliphatic polyisocyanates(such as 1,4-tetramethylene diisocyanate, and 1,6-hexamethylenediisocyanate). Cycloaliphatic diisocyanates, such as, for example1,4-cyclohexyl diisocyanate and isophorone diisocyanate can be employed.

In one embodiment, the present invention is directed to a coatingcomposition formed from components comprising: (a) at least onecarbamate functional material comprising at least one carbamate groupblocked with a hydrolyzable silyl group, and (b) at least one curingagent reactive with the carbamate group of (a).

In an alternative embodiment, silyl groups can be used to block carboxylfunctional groups of carboxyl functional materials. In one embodiment,the present invention is directed to a coating composition formed fromcomponents comprising (a) at least one carboxyl functional non-vinylmaterial comprising at least one carboxyl group blocked with ahydrolyzable silyl group, and (b) at least one curing agent reactivewith the carboxyl group of (a).

In an alternative embodiment, silyl groups can be used to block amidefunctional groups of amide functional materials. In one embodiment, thepresent invention is directed to a coating composition formed fromcomponents comprising (a) at least one amide functional non-vinylmaterial comprising at least one amide group blocked with a hydrolyzablesilyl group, and (b) at least one curing agent reactive with the amidegroup of (a).

In one embodiment, the present invention is directed to compositions aspreviously described wherein the silyl-blocked material, when added tothe other components which form the composition, is present in thecomposition in an amount ranging from 0.1 to 90 weight percent based ontotal weight of the resin solids of the components which form thecomposition. As used herein “based on total weight of the resin solids”of the composition means that the amount of the component added duringthe formation of the composition is based upon the total weight of thesolids (non-volatiles) of any film-forming component, any polysiloxane,any curing agent present during the formation of the coatingcomposition, and any silyl-blocked material present, but not includingthe particles, any solvent, or any additive solids such as hinderedamine stabilizers, UV light absorbers, catalysts, flow modifiers, andpigments including extender pigments and fillers.

In another embodiment, the present invention is directed to compositionsas previously described wherein the at least one hydroxyl functionalnon-vinyl material having at least one alcoholic hydroxyl group blockedwith a hydrolyzable silyl group, when added to the other componentswhich form the composition, is present in the composition in an amountof at least 0.1 weight percent based on total weight of the resin solidsof the components which form the composition.

In another embodiment, the present invention is directed to compositionsas previously described wherein the at least one hydroxyl functionalnon-vinyl material having at least one alcoholic hydroxyl group blockedwith a hydrolyzable silyl group, when added to the other componentswhich form the composition, is present in the composition in an amountgreater than 1 weight percent based on total weight of the resin solidsof the components which form the composition.

In another embodiment, the present invention is directed to compositionsas previously described wherein the at least one hydroxyl functionalnon-vinyl material having at least one alcoholic hydroxyl group blockedwith a hydrolyzable silyl group, when added to the other componentswhich form the composition, is present in the composition in an amountranging from 15 weight percent to 85 weight percent based on totalweight of the resin solids of the components which form the composition.

In another embodiment, the present invention is directed to compositionsas previously described wherein the at least one hydroxyl functionalnon-vinyl material having at least one alcoholic hydroxyl group blockedwith a hydrolyzable silyl group, when added to the other componentswhich form the composition, is present in the composition in an amountof less than 90 weight percent based on total weight of the resin solidsof the components which form the composition.

In another embodiment, the present invention is directed to compositionsas previously described wherein the at least one hydroxyl functionalnon-vinyl material having at least one alcoholic hydroxyl group blockedwith a hydrolyzable silyl group, when added to the other componentswhich form the composition, is present in the composition in an amountof less than 60 weight percent based on total weight of the resin solidsof the components which form the composition.

In another embodiment, the present invention is directed to compositionsas previously described wherein the at least one hydroxyl functionalnon-vinyl material having at least one alcoholic hydroxyl group blockedwith a hydrolyzable silyl group, when added to the other componentswhich form the composition, is present in the composition in an amountof less than 30 weight percent based on total weight of the resin solidsof the components which form the composition.

In another embodiment, the present invention is directed to compositionsas previously described wherein the at least one hydroxyl functionalnon-vinyl material having at least one alcoholic hydroxyl group blockedwith a hydrolyzable silyl group, when added to the other componentswhich form the composition, is present in the composition in an amountof less than 10 weight percent based on total weight of the resin solidsof the components which form the composition. The weight percent ofsilyl blocked material can range between any combination of these valuesinclusive of the recited ranges.

The coating compositions of the present invention comprise at least onecuring agent. In one embodiment, the curing agent is selected fromaminoplast resins, polyisocyanates, blocked polyisocyanates, triazinederivatives of isocyanates, anhydrides, polyepoxides, and mixtures ofthe foregoing.

As used herein, the term “cure” as used in connection with acomposition, e.g., “a cured composition,” shall mean that at least aportion of the crosslinkable components which form the composition areat least partially crosslinked. In certain embodiments of the presentinvention, the crosslink density of the crosslinkable components, i.e.,the degree of crosslinking, ranges from 5% to 100% of completecrosslinking. In other embodiments, the crosslink density ranges from35% to 85% of full crosslinking. In other embodiments, the crosslinkdensity ranges from 50% to 85% of full crosslinking. One skilled in theart will understand that the presence and degree of crosslinking, i.e.,the crosslink density, can be determined by a variety of methods, suchas dynamic mechanical thermal analysis (DMTA) using a TA Instruments DMA2980 DMTA analyzer conducted under nitrogen. This method determines theglass transition temperature and crosslink density of free films ofcoatings or polymers. These physical properties of a cured material arerelated to the structure of the crosslinked network.

According to this method, the length, width, and thickness of a sampleto be analyzed are first measured, the sample is tightly mounted to thePolymer Laboratories MK III apparatus, and the dimensional measurementsare entered into the apparatus. A thermal scan is run at a heating rateof 3° C./min, a frequency of 1 Hz, a strain of 120%, and a static forceof 0.01N, and sample measurements occur every two seconds. The mode ofdeformation, glass transition temperature, and crosslink density of thesample can be determined according to this method. Higher crosslinkdensity values indicate a higher degree of crosslinking in the coating.

In one embodiment, the curing agent is an aminoplast. Aminoplast resins,which comprise phenoplasts, as curing agents for hydroxyl and carbamatefunctional group-containing materials are well known in the art.Suitable aminoplasts, such as, for example those discussed above, areknown to those of ordinary skill in the art. Aminoplasts can be obtainedfrom the condensation reaction of formaldehyde with an amine or amide.Nonlimiting examples of amines or amides include melamine, urea, orbenzoguanamine. Condensates with other amines or amides can be used, forexample aldehyde condensates of glycoluril, which give a high meltingcrystalline product useful in powder coatings. While the aldehyde usedis most often formaldehyde, other aldehydes such as acetaldehyde,crotonaldehyde, and benzaldehyde can be used.

The aminoplast contains imino and methylol groups and in certaininstances at least a portion of the methylol groups are etherified withan alcohol to modify the cure response. Any monohydric alcohol can beemployed for this purpose including methanol, ethanol, n-butyl alcohol,isobutanol, and hexanol.

Nonlimiting examples of aminoplasts include melamine-, urea-, orbenzoguanamine-formaldehyde condensates, in certain instances monomericand at least partially etherified with one or more alcohols containingfrom one to four carbon atoms. Nonlimiting examples of suitableaminoplast resins are commercially available, for example from CytecIndustries, Inc. under the trademark CYMEL®, and from Solutia, Inc.under the trademark RESIMENE®.

In another embodiment, the present invention is directed to coatingcompositions as previously described wherein the aminoplast curingagent, when added to the other components which form the coatingcomposition, is generally present in an amount ranging from 2 weightpercent to 65 weight percent based on total weight of the resin solidsof the components from which the coating composition is formed.

Other curing agents suitable for use include, but are not limited to,polyisocyanate curing agents. As used herein, the term “polyisocyanate”is intended to include blocked (or capped) polyisocyanates as well asunblocked polyisocyanates. The polyisocyanate can be an aliphatic or anaromatic polyisocyanate, or a mixture of the foregoing two.Diisocyanates can be used, although higher polyisocyanates such asisocyanurates of diisocyanates are often used. Higher polyisocyanatesalso can be used in combination with diisocyanates. Isocyanateprepolymers, for example reaction products of polyisocyanates withpolyols also can be used. Mixtures of polyisocyanate curing agents canbe used.

If the polyisocyanate is blocked or capped, any suitable aliphatic,cycloaliphatic, or aromatic alkyl monoalcohol known to those skilled inthe art can be used as a capping agent for the polyisocyanate. Othersuitable capping agents include oximes and lactams. When used, thepolyisocyanate curing agent is typically present, when added to theother components in the coating composition, in an amount ranging from 5to 65 weight percent, can be present in an amount ranging from 10 to 45weight percent, and often are present in an amount ranging from 15 to 40percent by weight based on the total weight of the resin solids of thecomponents which form the coating composition.

Other useful curing agents comprise triazine derived isocyanates suchas, for example the tricarbamoyl triazine compounds described in detailin U.S. Pat. No. 5,084,541, which is incorporated by reference herein.When used, the triazine derived isocyanates can be present, when addedto the other components in the coating composition, in an amount rangingup to 20 weight percent, and can be present in an amount ranging from 1to 20 weight percent, based on the total weight of the resin solids ofthe components which form the coating composition.

Anhydrides as curing agents for hydroxyl functional group-containingmaterials also are well known in the art and can be used in the presentinvention. Nonlimiting examples of anhydrides suitable for use as curingagents in the coating compositions of the invention include thosecomprising at least two carboxylic acid anhydride groups per moleculewhich are derived from a mixture of monomers comprising an ethylenicallyunsaturated carboxylic acid anhydride and at least one vinyl co-monomer,for example styrene, alpha-methyl styrene, vinyl toluene, and the like.Nonlimiting examples of suitable ethylenically unsaturated carboxylicacid anhydrides include maleic anhydride, citraconic anhydride, anditaconic anhydride. Alternatively, the anhydride can be an anhydrideadduct of a diene polymer such as maleinized polybutadiene or amaleinized copolymer of butadiene, for example a butadiene/styrenecopolymer. These and other suitable anhydride curing agents aredescribed in U.S. Pat. No. 4,798,746 at column 10, lines 16–50, and inU.S. Pat. No. 4,732,790 at column 3, lines 41–57, both of which areincorporated herein by reference.

When desired, appropriate mixtures of curing agents may be used. Itshould be mentioned that coating compositions can be formulated as aone-component coating composition where a curing agent such as anaminoplast resin and/or a triazine compound such as those describedabove is admixed with other coating composition components. Theone-component coating composition can be storage stable as formulated.Alternatively, coating compositions can be formulated as a two-componentcoating composition where a polyisocyanate curing agent such as thosedescribed above can be added to a pre-formed admixture of the othercoating composition components just prior to application. The pre-formedadmixture can comprise curing agents such as aminoplast resins and/ortriazine compounds such as those described above.

Generally, the curing agent, when added to other components that formthe coating composition, is present in the coating composition in anamount ranging from 5 to 95 weight percent based on total weight of theresin solids of the components from which the coating composition isformed. In one embodiment, the curing agent, when added to othercomponents that form the coating composition, is present in the coatingcomposition in an amount ranging from 15 to 50 weight percent based ontotal weight of the resin solids of the components from which thecoating composition is formed.

In another embodiment, the curing agent, when added to other componentsthat form the coating composition, is present in the coating compositionin an amount greater than 15 weight percent based on total weight of theresin solids of the components from which the coating composition isformed.

The components from which the coating composition are formed further cancomprise at least one polysiloxane, different from component (a),comprising at least one reactive functional group. In one embodiment, atleast one of functional groups of the at least one polysiloxane can beblocked with a silyl group such as are described above.

In one embodiment, the at least one polysiloxane different fromcomponent (a) comprises at least one of the following structural units(I)R¹ _(n)R² _(m)SiO_((4-n-m)/2)  (I)

wherein each substituent group R¹, which may be identical or different,represents a group selected from H, OH, a monovalent hydrocarbon group,and a monovalent siloxane group, each substituent group R², which may beidentical or different, and which may be identical or different from R¹,represents a group comprising at least one reactive functional group.

It should be understood that the “at least one polysiloxane having atleast one structural unit (I)” above is a polymer that contains at leasttwo Si atoms per molecule. Again, as used herein, the term “polymer” inmeant to encompass oligomer, and includes without limitation bothhomopolymers and copolymers. It should also be understood that the atleast one polysiloxane can include linear, branched, dendritic or cyclicpolysiloxanes.

Also, as used herein, the term “reactive” refers to a functional groupthat forms a covalent bond with another functional group underconditions sufficient to cure the composition.

Each of m and n depicted in the at least one structural unit (I) abovefulfill the requirements of 0<n<4, 0<m<4 and 2≦(m+n)<4. When (m+n) is 3,the value represented by n can be 2 and the value represented by m is 1.Likewise, when (m+n) is 2, the value represented by each of n and m is1.

As used herein, a “monovalent hydrocarbon group” means a monovalentgroup having a backbone repeat unit based exclusively on carbon. As usedherein, “monovalent” refers to a substituent group that, as asubstituent group, forms only one single, covalent bond. For example amonovalent group on the at least one polysiloxane will form one singlecovalent bond to a silicon atom in the backbone of the at least onepolysiloxane polymer. As used herein, “hydrocarbon groups” are intendedto encompass both branched or unbranched hydrocarbon groups.

Thus, when referring to a “monovalent hydrocarbon group,” thehydrocarbon group can be branched or unbranched, acyclic or cyclic,saturated or unsaturated, or aromatic, and can contain from 1 to 24 (orin the case of an aromatic group from 3 to 24) carbon atoms. Nonlimitingexamples of such hydrocarbon groups include alkyl, alkoxy, aryl,alkaryl, and alkoxyaryl groups. Nonlimiting examples of lower alkylgroups include, for example methyl, ethyl, propyl, and butyl groups. Asused herein, “lower alkyl” refers to alkyl groups having from 1 to 6carbon atoms. One or more of the hydrogen atoms of the hydrocarbon canbe substituted with heteroatoms. As used herein, “heteroatoms” meanselements other than carbon, for example oxygen, nitrogen, and halogenatoms.

As used herein, “siloxane” means a group comprising a backbonecomprising two or more —SiO— groups. The siloxane groups represented byR¹ and R (discussed below) can be branched or unbranched, and linear orcyclic. The siloxane groups can be substituted with pendant organicsubstituent groups, for example alkyl, aryl, and alkaryl groups. Theorganic substituent groups can be substituted with heteroatoms, forexample oxygen, nitrogen, and halogen atoms, reactive functional groups,for example those reactive functional groups discussed above withreference to R², and mixtures of any of the foregoing.

In another embodiment, each substituent group R², which may be identicalor different, represents a group comprising at least one reactivefunctional group selected from a hydroxyl group, a carboxyl group, anisocyanate group, a blocked polyisocyanate group, a primary amine group,a secondary amine group, an amide group, a carbamate group, a ureagroup, a urethane group, a vinyl group, an unsaturated ester group suchas an acrylate group and a methacrylate group, a maleimide group, afumarate group, an onium salt group such as a sulfonium group and anammonium group, an anhydride group, a hydroxy alkylamide group, and anepoxy group, wherein m and n fulfill the requirements of O<n<4, O<m<4and 2≦(m+n)<4.

In one embodiment, the present invention is directed to a coatingcomposition as previously described, wherein the at least onepolysiloxane comprises at least two reactive functional groups.

In another embodiment, the present invention is directed to a coatingcomposition as previously described, wherein at least one R² grouprepresents a group comprising at least one reactive functional groupselected from a hydroxyl group and a carbamate group. In yet anotherembodiment, the present invention is directed to a coating compositionas previously described, wherein at least one R² group represents agroup comprising at least two reactive functional groups selected from ahydroxyl group and a carbamate group. In another embodiment, the presentinvention is directed to a coating composition as previously described,wherein at least one R² group represents a group comprising anoxyalkylene group and at least two hydroxyl groups.

In one embodiment, the present invention is directed to a coatingcomposition as previously described, wherein the at least onepolysiloxane has the following structure (II) or (III):

wherein: m has a value of at least 1; m′ ranges from 0 to 75; n rangesfrom 0 to 75; n′ ranges from 0 to 75; each R, which may be identical ordifferent, is selected from H, OH, a monovalent hydrocarbon group, amonovalent siloxane group, and mixtures of any of the foregoing; and—R^(a) comprises the following structure (IV):—R³—X  (IV)

wherein —R³ is selected from an alkylene group, an oxyalkylene group, analkylene aryl group, an alkenylene group, an oxyalkenylene group, and analkenylene aryl group; and X represents a group which comprises at leastone reactive functional group selected from a hydroxyl group, a carboxylgroup, an isocyanate group, a blocked polyisocyanate group, a primaryamine group, a secondary amine group, an amide group, a carbamate group,a urea group, a urethane group, a vinyl group, an unsaturated estergroup such as an acrylate group and a methacrylate group, a maleimidegroup, a fumarate group, an onium salt group such as a sulfonium groupand an ammonium group, an anhydride group, a hydroxy alkylamide group,and an epoxy group.

As used herein, “alkylene” refers to an acyclic or cyclic, saturatedhydrocarbon group having a carbon chain length of from C₂ to C₂₅.Nonlimiting examples of suitable alkylene groups include, but are notlimited to, those derived from propenyl, 1-butenyl, 1-pentenyl,1-decenyl, and 1-heneicosenyl, such as, for example (CH₂)₃, (CH₂)₄,(CH₂)₅, (CH₂)₁₀, and (CH₂)₂₃, respectively, as well as isoprene andmyrcene.

As used herein, “oxyalkylene” refers to an alkylene group containing atleast one oxygen atom bonded to, and interposed between, two carbonatoms and having an alkylene carbon chain length of from C₂ to C₂₅.Nonlimiting examples of suitable oxyalkylene groups include thosederived from trimethylolpropane monoallyl ether, trimethylolpropanediallyl ether, pentaerythritol monoallyl ether, polyethoxylated allylalcohol, and polypropoxylated allyl alcohol, such as—(CH₂)₃OCH₂C(CH₂OH)₂(CH₂CH₂—).

As used herein, “alkylene aryl” refers to an acyclic alkylene groupsubstituted with at least one aryl group, for example, phenyl, andhaving an alkylene carbon chain length of C₂ to C₂₅. The aryl group canbe further substituted, if desired. Nonlimiting examples of suitablesubstituent groups for the aryl group include, but are not limited to,hydroxyl groups, benzyl groups, carboxylic acid groups, and aliphatichydrocarbon groups. Nonlimiting examples of suitable alkylene arylgroups include, but are not limited to, those derived from styrene and3-isopropenyl-∝,∝-dimethylbenzyl isocyanate, such as —(CH₂)₂C₆H₄— and—CH₂CH(CH₃)C₆H₃(C(CH₃)₂(NCO). As used herein, “alkenylene” refers to anacyclic or cyclic hydrocarbon group having one or more double bonds andhaving an alkenylene carbon chain length of C₂ to C₂₅. Nonlimitingexamples of suitable alkenylene groups include those derived frompropargyl alcohol and acetylenic diols, for example,2,4,7,9-tetramethyl-5-decyne-4,7-diol which is commercially availablefrom Air Products and Chemicals, Inc. of Allentown, Pa. as SURFYNOL 104.

Formulae (II) and (III) are diagrammatic, and are not intended to implythat the parenthetical portions are necessarily blocks, although blocksmay be used where desired. In some cases the polysiloxane may comprise avariety of siloxane units. This is increasingly true as the number ofsiloxane units employed increases, and especially true when mixtures ofa number of different siloxane units are used. In those instances wherea plurality of siloxane units are used and it is desired to form blocks,oligomers can be formed which can be joined to form the block compound.By judicious choice of reactants, compounds having an alternatingstructure or blocks of alternating structure may be used.

In one embodiment, the present invention is directed to a coatingcomposition prepared from components as previously described comprisingthe polysiloxane as previously described in which the substituent groupR³ represents an oxyalkylene group. In another embodiment, R³ representsan oxyalkylene group, and X represents a group which comprises at leasttwo reactive functional groups.

In another embodiment, the present invention is directed to any coatingcomposition prepared from components as previously described comprisingat least one polysiloxane having the structure (II) or (III) describedabove, wherein (n+m) ranges from 2 to 9. In yet another embodiment, thecomponents can comprise at least one polysiloxane having the structure(II) or (III) described above, (n+m) ranges from 2 to 3. In anotherembodiment, the components can comprise at least one polysiloxane havingthe structure (II) or (III) described above, (n′+m′) ranges from 2 to 9.In another embodiment, the components can comprise at least onepolysiloxane having the structure (II) or (III) described above, (n′+m′)ranges from 2 to 3.

In one embodiment, the present invention is directed to any coatingcomposition as previously described in which the components comprise atleast one polysiloxane in which X represents a group comprising at leastone reactive functional group selected from a hydroxyl group and acarbamate group. In another embodiment, the present invention isdirected to polysiloxane as a component as previously described whereinX represents a group which comprises at least two hydroxyl groups. Inyet another embodiment, the present invention is directed topolysiloxane as a component as previously described wherein X representsa group which comprises at least one group selected from H, amonohydroxy-substituted organic group, and a group having the followingstructure (V):R⁴—(CH₂—OH)_(p)  (V)

-   -   wherein the substituent group R⁴ represents

-   -   when p is 2 and the substituent group R³ represents a C₁ to C₄        alkylene group, or    -   the substituent group R⁴ represents

-   -    when p is 3,

wherein at least a portion of X represents a group having the structure(V). In another embodiment, the present invention is directed to anycured composition as previously described wherein m is 2 and p is 2.

In an embodiment of the present invention, the at least one polysiloxaneis nonreactive with the particles.

In one embodiment, the present invention is directed to any coatingcomposition as previously described comprising at least one polysiloxanehaving the structure (II) or (III), wherein, if no curing agent ispresent, and if the at least one polysiloxane is a partial condensate ofa silanol, then less than 70% by weight of the partial condensate is thepartial condensate of CH₃Si(OH)₃. These components used in these variousembodiments can be selected from the coating components discussed above,and additional components also can be selected from those recited above.

In another embodiment, the present invention is directed to any coatingcomposition as previously described, wherein the components from whichthe composition is formed comprise at least one polysiloxane which isthe reaction product of at least the following reactants: (i) at leastone polysiloxane of the formula (VI):

wherein each substituent group R, which may be identical or different,represents a group selected from H, OH, a monovalent hydrocarbon group,a monovalent siloxane group, and mixtures of any of the foregoing; atleast one of the groups represented by R is H, and n′ ranges from 0 to100, also can range from 0 to 10, and can further range from 0 to 5 suchthat the percent of SiH content of the polysiloxane ranges from 2 to 50percent, and can range from 5 to 25 percent; and (ii) at least onemolecule which comprises at least one reactive functional group selectedfrom a hydroxyl group, a carboxyl group, an isocyanate group, a blockedpolyisocyanate group, a primary amine group, a secondary amine group, anamide group, a carbamate group, a urea group, a urethane group, a vinylgroup, an unsaturated ester group such as an acrylate group and amethacrylate group, a maleimide group, a fumarate group, an onium saltgroup such as a sulfonium group and an ammonium group, an anhydridegroup, a hydroxy alkylamide group, and an epoxy group, and at least oneunsaturated bond capable of undergoing a hydrosilylation reaction. Inone embodiment, the at least one functional group is selected fromprimary hydroxyl groups.

It should be appreciated that the various R groups can be the same ordifferent, and, in certain embodiments, the R groups will be entirelymonovalent hydrocarbon groups or will be a mixture of different groupssuch as monovalent hydrocarbon groups and hydroxyl groups.

In another embodiment, this reaction product is ungelled. As usedherein, “ungelled” refers to a reaction product that is substantiallyfree of crosslinking and has an intrinsic viscosity when dissolved in asuitable solvent, as determined, for example in accordance withASTM-D1795 or ASTM-D4243. The intrinsic viscosity of the reactionproduct is an indication of its molecular weight. A gelled reactionproduct, on the other hand, since it is of an extremely high molecularweight, will have an intrinsic viscosity too high to measure. As usedherein, a reaction product that is “substantially free of crosslinking”refers to a reaction product that has a weight average molecular weight(Mw), as determined by gel permeation chromatography, of less than1,000,000.

It also should be noted that the level of unsaturation contained inreactant (ii) above, can be selected to obtain an ungelled reactionproduct. In other words, when a polysiloxane containing silicon hydride(i) having a higher average value of Si—H functionality is used,reactant (ii) can have a lower level of unsaturation. For example thepolysiloxane containing silicon hydride (i) can be a low molecularweight material where n′ ranges from 0 to 5 and the average value ofSi—H functionality is two or less. In this case, reactant (ii) cancontain two or more unsaturated bonds capable of undergoinghydrosilylation reaction without the occurrence of gelation.

Nonlimiting examples of polysiloxanes containing silicon hydride (i)include 1,1,3,3-tetramethyl disiloxane where n′ is 0 and the averageSi—H functionality is two; and polymethyl polysiloxane containingsilicon hydride, where n′ ranges from 4 to 5 and the average Si—Hfunctionality is approximately two, such as is commercially availablefrom BASF Corporation as MASILWAX BASE®.

Materials for use as reactant (ii) above can include hydroxyl functionalgroup-containing allyl ethers such as those selected fromtrimethylolpropane monoallyl ether, pentaerythritol monoallyl ether,trimethylolpropane diallyl ether, polyoxyalkylene alcohols such aspolyethoxylated alcohol, polypropoxylated alcohol, and polybutoxylatedalcohol, undecylenic acid-epoxy adducts, allyl glycidyl ether-carboxylicacid adducts, and mixtures of any of the foregoing. Mixtures of hydroxylfunctional polyallyl ethers with hydroxyl functional monoallyl ethers orallyl alcohols are suitable as well. In certain instances, reactant (ii)can contain at least one unsaturated bond in a terminal position.Reaction conditions and the ratio of reactants (i) and (ii) are selectedso as to form the desired functional group.

The hydroxyl functional group-containing polysiloxane can be prepared byreacting a polysiloxane containing hydroxyl functional groups with ananhydride to form the half-ester acid group under reaction conditionsthat favor only the reaction of the anhydride and the hydroxylfunctional groups, and avoid further esterification from occurring.Nonlimiting examples of suitable anhydrides include hexahydrophthalicanhydride, methyl hexahydrophthalic anhydride, phthalic anhydride,trimellitic anhydride, succinic anhydride, chlorendic anhydride, alkenylsuccinic anhydride, and substituted alkenyl anhydrides such as octenylsuccinic anhydride, and mixtures of any of the foregoing.

The half-ester group-containing reaction product thus prepared can befurther reacted with a monoepoxide to form a polysiloxane containing atleast one secondary hydroxyl group. Nonlimiting examples of suitablemonoepoxides are phenyl glycidyl ether, n-butyl glycidyl ether, cresylglycidyl ether, isopropyl glycidyl ether, glycidyl versatate, forexample CARDURA E available from Shell Chemical Co., and mixtures of anyof the foregoing.

In another embodiment, the present invention is directed to coatingcompositions as previously described wherein the components from whichthe coating compositions are formed comprise at least one polysiloxanewhich is a carbamate functional group-containing polysiloxane whichcomprises the reaction product of at least the following reactants:

(i) at least one polysiloxane containing silicon hydride of structure(VI) above where R and n′ are as described above for that structure;

(ii) at least one hydroxyl functional group-containing materialcomprising one or more unsaturated bonds capable of undergoinghydrosilylation reaction as described above; and

(iii) at least one low molecular weight carbamate functional material,comprising the reaction product of an alcohol or glycol ether and aurea.

Examples of such “low molecular weight carbamate functional material”include, but are not limited to, alkyl carbamates such as methylcarbamate and hexyl carbamates, glycol ether carbamates described inU.S. Pat. Nos. 5,922,475 and 5,976,701, which are incorporated herein byreference.

The carbamate functional groups can be incorporated into at least onepolysiloxane by into the at least one polysiloxane with the lowmolecular weight carbamate functional material via a“transcarbamoylation” process. The low molecular weight carbamatefunctional material, which can be derived from an alcohol or glycolether, can react with free hydroxyl groups of a polyol, that is,material comprising an average of two or more hydroxyl groups permolecule, yielding a carbamate functional material and the originalalcohol or glycol ether. Reaction conditions and the ratio of reactants(i), (ii) and (iii) are selected so as to form the desired groups.

Examples of such “low molecular weight carbamate functional material”include, but are not limited to, alkyl carbamates such as methylcarbamate and hexyl carbamates, and glycol ether carbamates such asthose described in U.S. Pat. Nos. 5,922,475 and 5,976,701, which areincorporated herein by reference.

The low molecular weight carbamate functional material can be preparedby reacting the alcohol or glycol ether with urea in the presence of acatalyst such as butyl stannoic acid. Nonlimiting examples of suitablealcohols include lower molecular weight aliphatic, cycloaliphatic andaromatic alcohols, for example methanol, ethanol, propanol, butanol,cyclohexanol, 2-ethylhexanol, and 3-methylbutanol. Nonlimiting examplesof suitable glycol ethers include ethylene glycol methyl ether, andpropylene glycol methyl ether. The incorporation of carbamate functionalgroups into the at least one hydroxyl functional non-vinyl material alsocan be achieved by reacting isocyanic acid with free hydroxyl groups ofthe at least one hydroxyl functional non-vinyl material.

As aforementioned, in addition to or in lieu of hydroxyl and/orcarbamate functional groups, at least one polysiloxane can contain oneor more other reactive functional groups such as carboxyl groups,isocyanate groups, blocked isocyanate groups, carboxylate groups,primary amine groups, secondary amine groups, tertiary amine groups,amide groups, urea groups, urethane groups, acrylate groups, vinylgroups, epoxy groups, and mixtures of any of the foregoing.

When the at least one polysiloxane contains carboxyl functional groups,into the at least one polysiloxane can be prepared by reacting the atleast one polysiloxane as described above with a polycarboxylic acid oranhydride. Nonlimiting examples of polycarboxylic acids suitable for useinclude adipic acid, succinic acid, and dodecanedioic acid. Nonlimitingexamples of suitable anhydrides include those described above. Reactionconditions and the ratio of reactants are selected so as to form thedesired functional groups.

In the case where the at least one polysiloxane contains one or moreisocyanate functional groups, the at least one polysiloxane can beprepared by reacting at least one polysiloxane as described above with apolyisocyanate, such as a diisocyanate. Nonlimiting examples of suitablepolyisocyanates include aliphatic polyisocyanates, such as, for examplealiphatic diisocyanates, for example 1,4-tetramethylene diisocyanate and1,6-hexamethylene diisocyanate; cycloaliphatic polyisocyanates, forexample 1,4-cyclohexyl diisocyanate, isophorone diisocyanate, andα,α-xylylene diisocyanate; and aromatic polyisocyanates, for example4,4′-diphenylmethane diisocyanate, 1,3-phenylene diisocyanate, andtolylene diisocyanate. These and other suitable polyisocyanates aredescribed in more detail in U.S. Pat. No. 4,046,729, at column 5, line26 to column 6, line 28, incorporated herein by reference. Reactionconditions and the ratio of reactants are selected so as to form thedesired functional groups.

The substituent group X in structure (IV) can comprise a polymericurethane or urea-containing material which is terminated withisocyanate, hydroxyl, primary or secondary amine functional groups, ormixtures of any of the foregoing. When the substituent group X comprisessuch functional groups, the at least one polysiloxane can be thereaction product of the at least one polysiloxane as described above,one or more polyisocyanates and, optionally, one or more compoundscomprising at least two active hydrogen atoms per molecule selected fromhydroxyl groups, primary amine groups, and secondary amine groups.

Nonlimiting examples of suitable polyisocyanates are those describedabove. Nonlimiting examples of compounds comprising at least two activehydrogen atoms per molecule include polyols and polyamines containingprimary and/or secondary amine groups.

Nonlimiting examples of suitable polyols include polyalkylene etherpolyols, including thio ethers; polyester polyols, including polyhydroxypolyesteramides; and hydroxyl-containing polycaprolactones andhydroxy-containing acrylic interpolymers. Also useful are polyetherpolyols formed from the oxyalkylation of various polyols, for exampleglycols such as ethylene glycol, 1,6-hexanediol, Bisphenol A, and thelike, or higher polyols such as trimethylolpropane, pentaerythritol andthe like. Polyester polyols also can be used. These and other suitablepolyols are described in U.S. Pat. No. 4,046,729 at column 7, line 52 tocolumn 8, line 9; column 8, line 29 to column 9, line 66; and U.S. Pat.No. 3,919,315 at column 2, line 64 to column 3, line 33, bothincorporated herein by reference.

Nonlimiting examples of suitable polyamines include primary or secondarydiamines or polyamines in which the groups attached to the nitrogenatoms can be saturated or unsaturated, aliphatic, alicyclic, aromatic,aromatic-substituted-aliphatic, aliphatic-substituted-aromatic andheterocyclic. Exemplary suitable aliphatic and alicyclic diaminesinclude 1,2-ethylene diamine, 1,2-porphylene diamine, 1,8-methanediamine, isophorone diamine, propane-2,2-cyclohexyl amine, and the like.Suitable aromatic diamines include phenylene diamines and the toluenediamines, for example o-phenylene diamine and p-tolylene diamine. Theseand other suitable polyamines are described in detail in U.S. Pat. No.4,046,729 at column 6, line 61 to column 7, line 26, incorporated hereinby reference.

In one embodiment, the substituent group X of the structure (IV) cancomprise a polymeric ester-containing group which is terminated withhydroxyl or carboxylic acid functional groups. When X is such a group,the at least one polysiloxane can be the reaction product of one or moreat least one polysiloxanes as described above, one or more materialscomprising at least one carboxylic acid functional group, and one ormore organic polyols. Nonlimiting suitable examples of materialscomprising at least one carboxylic acid functional group includecarboxylic acid group-containing polymers well-known in the art, forexample carboxylic acid group-containing acrylic polymers, polyesterpolymers, and polyurethane polymers, such as those described in U.S.Pat. No. 4,681,811. Nonlimiting examples of suitable organic polyolsinclude those described above.

To form the at least one polysiloxane containing epoxy groups, the atleast one polysiloxane as described above can be further reacted with apolyepoxide. The polyepoxide can be an aliphatic or cycloaliphaticpolyepoxide or mixtures of any of the foregoing. Nonlimiting examples ofpolyepoxides suitable for use include epoxy functional acryliccopolymers prepared from at least one ethylenically unsaturated monomercomprising at least one epoxy group, for example glycidyl(meth)acrylateand allyl glycidyl ether, and one or more ethylenically unsaturatedmonomers which have no epoxy functionality. The preparation of suchepoxy functional acrylic copolymers is described in detail in U.S. Pat.No. 4,681,811 at column 4, line 52 to column 5, line 50, incorporatedherein by reference. Reaction conditions and the ratio of reactants areselected so as to form the desired functional groups.

Generally, the at least one polysiloxane, when added to other componentsthat form the coating composition, when present in the coatingcomposition is present in an amount ranging from 1 to 90 weight percentbased on total weight of the resin solids of the components from whichthe coating composition is formed. The weight percent of polysiloxanecan range between any combination of these values inclusive of therecited ranges.

In one embodiment, the components from which the coating composition isformed further can comprise a plurality of particles, wherein eachcomponent is different. As used herein, the phrase “each component isdifferent” refers to components which do not have the same chemicalstructure as other components in the composition. The particles can beformed from materials selected from polymeric and nonpolymeric inorganicmaterials, polymeric and nonpolymeric organic materials, compositematerials, and mixtures of any of the foregoing. As used herein, “formedfrom” denotes open, e.g., “comprising,” claim language. As such, it isintended that a composition “formed from” a list of recited componentsbe a composition comprising at least these recited components, and canfurther comprise other, nonrecited components, during the composition'sformation.

As used herein, the term “polymeric inorganic material” means apolymeric material having a backbone repeat unit based on an element orelements other than carbon. For more information see James Mark et al.,Inorganic Polymers, Prentice Hall Polymer Science and EngineeringSeries, (1992) at page 5, which is specifically incorporated byreference herein. Moreover, as used herein, the term “polymeric organicmaterials” means synthetic polymeric materials, semisynthetic polymericmaterials and natural polymeric materials, all of which have a backbonerepeat unit based on carbon.

An “organic material,” as used herein, means carbon containing compoundswherein the carbon is typically bonded to itself and to hydrogen, andoften to other elements as well, and excludes binary compounds such asthe carbon oxides, the carbides, carbon disulfide, etc.; such ternarycompounds as the metallic cyanides, metallic carbonyls, phosgene,carbonyl sulfide, etc.; and carbon-containing ionic compounds such asmetallic carbonates, for example calcium carbonate and sodium carbonate.See R. Lewis, Sr., Hawley's Condensed Chemical Dictionary, (12th Ed.1993) at pages 761–762, and M. Silberberg, Chemistry The MolecularNature of Matter and Change (1996) at page 586, which are specificallyincorporated by reference herein.

As used herein, the term “inorganic material” means any material that isnot an organic material.

As used herein, the term “composite material” means a combination of twoor more differing materials. The particles formed from compositematerials generally have a hardness at their surface that is differentfrom the hardness of the internal portions of the particle beneath itssurface. More specifically, the surface of the particle can be modifiedin any manner well known in the art, including, but not limited to,chemically or physically changing its surface characteristics usingtechniques known in the art.

For example a particle can be formed from a primary material that iscoated, clad or encapsulated with one or more secondary materials toform a composite particle that has a softer surface. In yet anotheralternative embodiment, particles formed from composite materials can beformed from a primary material that is coated, clad or encapsulated witha different form of the primary material. For more information onparticles useful in the present invention, see G. Wypych, Handbook ofFillers, 2nd Ed. (1999) at pages 15–202, which are specificallyincorporated by reference herein.

The particles suitable for use in the coating compositions of theinvention can comprise inorganic elements or compounds known in the art.Suitable particles can be formed from ceramic materials, metallicmaterials, and mixtures of any of the foregoing. Suitable ceramicmaterials comprise metal oxides, metal nitrides, metal carbides, metalsulfides, metal silicates, metal borides, metal carbonates, and mixturesof any of the foregoing. Specific, nonlimiting examples of metalnitrides are, for example boron nitride; specific, nonlimiting examplesof metal oxides are, for example zinc oxide; nonlimiting examples ofsuitable metal sulfides are, for example molybdenum disulfide, tantalumdisulfide, tungsten disulfide, and zinc sulfide; nonlimiting suitableexamples of metal silicates are, for example aluminum silicates andmagnesium silicates such as vermiculite.

The particles can comprise, for example a core of essentially a singleinorganic oxide such as silica in colloidal, fumed, or amorphous form,alumina or colloidal alumina, titanium dioxide, cesium oxide, yttriumoxide, colloidal yttria, zirconia, e.g., colloidal or amorphouszirconia, and mixtures of any of the foregoing; or an inorganic oxide ofone type upon which is deposited an organic oxide of another type. Itshould be understood that when the cured composition of the invention isemployed as a transparent topcoat, for example as a clearcoat in amulti-component composite coating composition, particles should notseriously interfere with the optical properties of the curedcomposition. As used herein, “transparent” means that the cured coatinghas a BYK Haze index of less than 50 as measured using a BYK/Haze Glossinstrument.

Nonpolymeric, inorganic materials useful in forming the particles of thepresent invention comprise inorganic materials selected from graphite,metals, oxides, carbides, nitrides, borides, sulfides, silicates,carbonates, sulfates, and hydroxides. A nonlimiting example of a usefulinorganic oxide is zinc oxide. Nonlimiting examples of suitableinorganic sulfides include molybdenum disulfide, tantalum disulfide,tungsten disulfide, and zinc sulfide. Nonlimiting examples of usefulinorganic silicates include aluminum silicates and magnesium silicates,such as vermiculite. Nonlimiting examples of suitable metals includemolybdenum, platinum, palladium, nickel, aluminum, copper, gold, iron,silver, alloys, and mixtures of any of the foregoing.

In one embodiment, the present invention is directed to curedcompositions as previously described wherein the particles are selectedfrom fumed silica, amorphous silica, colloidal silica, alumina,colloidal alumina, titanium dioxide, cesium oxide, yttrium oxide,colloidal yttria, zirconia, colloidal zirconia, and mixtures of any ofthe foregoing. In another embodiment, the present invention is directedto cured compositions as previously described wherein the particlesinclude colloidal silica. As disclosed above, these materials can besurface treated or untreated.

The coating composition can comprise precursors suitable for formingsilica particles in situ by a sol-gel process. The coating compositionaccording to the present invention can comprise alkoxy silanes which canbe hydrolyzed to form silica particles in situ. For exampletetraethylortho silicate can be hydrolyzed with an acid such ashydrochloric acid and condensed to form silica particles. Other usefulparticles include surface-modified silicas such as are described in U.S.Pat. No. 5,853,809 at column 6, line 51 to column 8, line 43, which isincorporated herein by reference.

In one embodiment of the present invention, the particles have ahardness value greater than the hardness value of materials that canabrade a polymeric coating or a polymeric substrate. Examples ofmaterials that can abrade the polymeric coating or polymeric substrateinclude, but are not limited to, dirt, sand, rocks, glass, carwashbrushes, and the like. The hardness values of the particles and thematerials that can abrade the polymeric coating or polymeric substratecan be determined by any conventional hardness measurement method, suchas Vickers or Brinell hardness, but is preferably determined accordingto the original Mohs' hardness scale which indicates the relativescratch resistance of the surface of a material on a scale of one toten. The Mohs' hardness values of several nonlimiting examples ofparticles formed from inorganic materials suitable for use in thepresent invention are given in Table A below.

TABLE A Particle material Mohs' hardness (original scale) Boron nitride2¹ Graphite 0.5–1² Molybdenum disulfide 1³ Talc   1–1.5⁴ Mica 2.8–3.2⁵Kaolinite 2.0–2.56 Gypsum 1.6–2⁷ Calcite (calcium carbonate) 3⁸ Calciumfluoride 4⁹ zinc oxide 4.5¹⁰ Aluminum 2.5¹¹ Copper 2.5–3¹² Iron   4–5¹³Gold 2.5–3¹⁴ Nickel 5¹⁵ Palladium 4.8¹⁶ Platinum 4.3¹⁷ Silver 2.5–4¹⁸Zinc sulfide 3.5–4¹⁹ ¹K. Ludema, Friction, Wear, Lubrication, (1996) atpage 27, which is hereby incorporated by reference. ²R. Weast (Ed.),Handbook of Chemistry and Physics, CRC Press (1975) at page F-22. ³R.Lewis, Sr., Hawley's Condensed Chemical Dictionary, (12th Ed. 1993) atpage 793, which is hereby incorporated by reference. ⁴Hawley's CondensedChemical Dictionary, (12th Ed. 1993) at page 1113, which is herebyincorporated by reference. ⁵Hawley's Condensed Chemical Dictionary,(12th Ed. 1993) at page 784, which is hereby incorporated by reference.⁶Handbook of Chemistry and Physics at page F-22. ⁷Handbook of Chemistryand Physics at page F-22. ⁸Friction, Wear, Lubrication at page 27.⁹Friction, Wear, Lubrication at page 27. ¹⁰Friction, Wear, Lubricationat page 27. ¹¹Friction, Wear, Lubrication at page 27. ¹²Handbook ofChemistry and Physics at page F-22. ¹³Handbook of Chemistry and Physicsat page F-22. ¹⁴Handbook of Chemistry and Physics at page F-22.¹⁵Handbook of Chemistry and Physics at page F-22. ¹⁶Handbook ofChemistry and Physics at page F-22. ¹⁷Handbook of Chemistry and Physicsat page F-22. ¹⁸Handbook of Chemistry and Physics at page F-22. ¹⁹R.Weast (Ed.), Handbook of Chemistry and Physics, CRC Press (71^(st) Ed.1990) at page 4–158.In one embodiment, the Mohs' hardness value of the particles is greaterthan 4.

In certain embodiments, the Mohs' hardness value of the particles, suchas silica, is greater than 6.

As mentioned above, the Mohs' hardness scale relates to the resistanceof a material to scratching. The present invention therefore furthercontemplates particles that have a hardness at their surface that isdifferent from the hardness of the internal portions of the particlebeneath its surface.

More specifically, and as discussed above, the surface of the particlecan be modified in any manner well known in the art, including, but notlimited to, chemically changing the particle's surface characteristicsusing techniques known in the art such that the surface hardness of theparticle is greater the hardness of the materials that can abrade thepolymeric coating or polymeric substrate while the hardness of theparticle beneath the surface is less than the hardness of the materialsthat can abrade the polymeric coating or polymeric substrate.

As another alternative, a particle can be formed from a primary materialthat is coated, clad or encapsulated with one or more secondarymaterials to form a composite material that has a harder surface.Alternatively, a particle can be formed from a primary material that iscoated, clad or encapsulated with a differing form of the primarymaterial to form a composite material that has a harder surface.

In one example, and without limiting the present invention, an inorganicparticle formed from an inorganic material such as silicon carbide oraluminum nitride can be provided with a silica, carbonate or nanoclaycoating to form a useful composite particle. In another nonlimitingexample, a silane coupling agent with alkyl side chains can interactwith the surface of an inorganic particle formed from an inorganic oxideto provide a useful composite particle having a “softer” surface. Otherexamples include cladding, encapsulating or coating particles formedfrom nonpolymeric or polymeric materials with differing nonpolymeric orpolymeric materials. A specific nonlimiting example of such compositeparticles is DUALITE™, which is a synthetic polymeric particle coatedwith calcium carbonate that is commercially available from Pierce andStevens Corporation of Buffalo, N.Y.

The particles can be formed from synthetic, organic polymeric materials.Nonlimiting examples of suitable organic polymeric materials include,but are not limited to, thermoset materials and thermoplastic materials.As used herein, a “thermoplastic” material is a material that softenswhen exposed to heat and returns to its original condition when cooledto room temperature. Nonlimiting examples of suitable thermoplasticmaterials include thermoplastic polyesters such as polyethyleneterephthalate, polybutylene terephthalate, and polyethylene naphthalate,polycarbonates, polyolefins such as polyethylene, polypropylene, andpolyisobutene, acrylic polymers such as copolymers of styrene and anacrylic acid monomer, and polymers containing methacrylate, polyamides,thermoplastic polyurethanes, vinyl polymers, and mixtures of any of theforegoing.

Nonlimiting examples of suitable thermoset materials include thermosetpolyesters, vinyl esters, epoxy materials, phenolics, aminoplasts,thermoset polyurethanes, and mixtures of any of the foregoing. Aspecific, nonlimiting example of a synthetic polymeric particle formedfrom an epoxy material is an epoxy microgel particle. As used herein, a“thermoset” material is a material that material solidifies or “sets”irreversibly when heated. A thermoset material has formed a crosslinkednetwork. As used herein, a polymeric material is “crosslinked” if it atleast partially forms a polymeric network. One skilled in the art willunderstand that the presence and degree of crosslinking (crosslinkdensity) can be determined by a variety of methods, such as dynamicmechanical thermal analysis (DMTA) using a TA Instruments DMA 2980 DMTAanalyzer conducted under nitrogen such as is described above. Thismethod determines the glass transition temperature and crosslink densityof free films of coatings or polymers. These physical properties of acured material are related to the structure of the crosslinked network.

The particles also can be hollow particles formed from materialsselected from polymeric and nonpolymeric inorganic materials, polymericand nonpolymeric organic materials, composite materials, and mixtures ofany of the foregoing. Nonlimiting examples of suitable materials fromwhich the hollow particles can be formed are described above. In oneembodiment, the hollow particles are hollow glass spheres.

The particles according to the present invention that are applied to thepolymeric substrate or polymeric coating, for example but not limitedto, the electrodeposited coating, the primer coating, or the topcoat,can be present in a dispersion, suspension or emulsion in a carrier.Nonlimiting examples of suitable carriers include, but are not limitedto, water, solvents, surfactants, or a mixture of any of the foregoing.Nonlimiting examples of suitable solvents include, but are not limitedto, mineral oil, alcohols such as methanol or butanol, ketones such asmethyl amyl ketone, aromatic hydrocarbons such as xylene, glycol etherssuch as ethylene glycol monobutyl ether, esters, aliphatics, andmixtures of any of the foregoing.

Prior to incorporation, one class of particles which can be usedaccording to the present invention includes sols, such as an organosol,of the particles. These sols can be of a wide variety of small-particle,colloidal silicas having an average particle size in ranges such asidentified above.

The colloidal silicas can be surface modified during or after theparticles are initially formed. These surface modified silicas maycontain on their surface chemically bonded carbon-containing moieties,as well as such groups as anhydrous SiO₂ groups and SiOH groups, variousionic groups physically associated or chemically bonded within thesurface of the silica, adsorbed organic groups, or combinations of anyof the foregoing, depending on the characteristics of the particularsilica desired. Such surface modified silicas are described in detail inU.S. Pat. No. 4,680,204, which is incorporated herein by reference.

Such materials can be prepared by a variety of techniques in variousforms, nonlimiting examples comprise organosols and mixed sols. As usedherein the term “mixed sols” is intended to include those dispersions ofcolloidal silica in which the dispersing medium comprises both anorganic liquid and water. Such small particle colloidal silicas arereadily available, are essentially colorless and have refractive indiceswhich permit their inclusion in compositions that, without additionalpigments or components known in the art to color and/or decrease thetransparency of such compositions, result in colorless, transparentcoatings.

Suitable nonlimiting examples of particles include colloidal silicas,such as those commercially available from Nissan Chemical Company underthe trademark ORGANOSILICASOLS™ such as ORGANOSILICASOL™ MT-ST, and fromClariant Corporation as HIGHLINK™; colloidal aluminas, such as thosecommercially available from Nalco Chemical under the trademark NALCO8676®; and colloidal zirconias, such as those commercially availablefrom Nissan Chemical Company under the trademark HIT-32M®.

The particles can be incorporated into the compositions of the inventionin the form of a stable dispersion. When the particles are in acolloidal form, the dispersions can be prepared by dispersing theparticles in a carrier under agitation and solvent that is present canbe removed under vacuum at ambient temperatures. In certain embodiments,the carrier can be other than a solvent, such as the surface activeagents described in detail below, including, but not limited to apolysiloxane containing reactive functional groups.

Alternatively, the dispersions can be prepared as described in U.S. Pat.Nos. 4,522,958 or 4,526,910, which are incorporated by reference herein.The particles can be “cold-blended” with the at least one hydroxylfunctional non-vinyl material prior to incorporation into the inventivecompositions. Alternatively, the particles can be post-added to anadmixture of any remaining composition components (including, but notlimited to the at least one hydroxyl functional non-vinyl material) anddispersed therein using dispersing techniques well-known in the art.

When the particles are in other than colloidal form, for example but notlimited to, agglomerate form, the dispersions can be prepared bydispersing the agglomerate in the carrier, for example but not limitedto, the at least one hydroxyl functional non-vinyl material, to stablydisperse the particles therein. Dispersion techniques such as grinding,milling, microfluidizing, or any other pigment dispersing techniqueswell known in the art of coatings formulation can be used.Alternatively, the particles can be dispersed by any other dispersiontechniques known in the art. If desired, the particles in other thancolloidal form can be post-added to an admixture of other compositioncomponents and dispersed therein using any dispersing techniques knownin the art.

In one embodiment, the present invention is directed to compositionswhich comprise a plurality of particles, wherein a first portion of theparticles is present in a surface region of the cured composition in aconcentration which is higher than a concentration of a second portionof particles which is present in a bulk region of the cured composition.

As used herein “surface region” of the cured composition means theregion which is generally parallel to the exposed air-surface of thecoated substrate and which has thickness generally extendingperpendicularly from the surface of the cured coating to a depth rangingfrom at least 20 nanometers to 150 nanometers beneath the exposedsurface. In certain embodiments, this thickness of the surface regionranges from at least 20 nanometers to 100 nanometers, and can range fromat least 20 nanometers to 50 nanometers. As used herein, “bulk region”of the cured composition means the region which extends beneath thesurface region and which is generally parallel to the surface of thecoated substrate. The bulk region has a thickness extending from itsinterface with the surface region through the cured coating to thesubstrate or coating layer beneath the cured composition.

In embodiments of the present invention in which the particles have anaverage particle size greater than 50 nanometers, the thickness of thesurface region generally extends perpendicularly from the surface of thecured coating to a depth equal to three times the average particle sizeof the particles, and this surface can extend to a depth equal to twotimes the average particle size of the particles.

The concentration of particles in the cured composition can becharacterized in a variety of ways. For example the average numberdensity of particles (i.e., the average number or population ofparticles per unit volume) dispersed in the surface region is greaterthan the average number density dispersed in the bulk region.Alternatively, the average volume fraction (i.e., volume occupied byparticles/total volume) or average weight percent per unit volume, i.e.,((the weight of particles within a unit volume of cured coating)/(totalweight of the unit volume of cured coating))×100% of the particlesdispersed in the surface region is greater than the average volumefraction or average weight percent of particles dispersed within thebulk region.

The concentration of particles (as characterized above) present in thesurface region of the cured coating can be determined, if desired, by avariety of surface analysis techniques well known in the art, such asTransmission Electron Microscopy (“TEM”), Surface Scanning ElectronMicroscopy (“X-SEM”), Atomic Force Microscopy (“AFM”), and X-rayPhotoelectron Spectroscopy.

For example the concentration of particles present in the surface regionof the cured coating may be determined by cross-sectional transmissionelectron microscopy techniques. A useful transmission electronmicroscopy method is described generally as follows. A coatingcomposition is applied to a substrate and cured under conditionsappropriate to the composition and substrate. Samples of the curedcoating are then removed or delaminated from the substrate and embeddedin a cured epoxy resin using techniques as are well known in the art.The embedded samples then can be microtomed at room temperature usingtechniques well known in the art, such as by forming a block face. Thesections can be cut using a 450 diamond knife edge mounted in a holderwith a “boat cavity” to hold water. During the cutting process, sectionsfloat to the surface of the water in the boat cavity. Once a few cutsreach an interference color of bright to dark gold (i.e., approximately100 to 150 nanometers thickness), individual samples typically arecollected onto a formvar-carbon coated grid and dried at ambienttemperature on a glass slide. The samples are then placed in a suitabletransmission electron microscope, such as a Philips CM12 TEM, andexamined at various magnifications, such as at 105,000× magnification,for documentation of particle concentration at the surface region, viaelectron micrography. The concentration of particles in a surface regionof a cured coating can be ascertained upon visual inspection of theelectron micrograph.

It should be understood that the particles can be present in the surfaceregion such that a portion of the particles at least partially protrudesabove the cured coating surface, essentially unprotected by an organiccoating layer. Alternatively, the particles can be present in thesurface region such that this organic coating layer lies between theparticles and the exposed air-surface interface of the surface region.

In one embodiment, the present invention is directed to curedcompositions as previously described wherein the particles have anaverage particle size less than 100 microns prior to incorporation intothe coating composition, and can have an average particle size less than50 microns prior to incorporation into the coating composition. Inanother embodiment, the present invention is directed to curedcompositions as previously described wherein the particles have anaverage particle size ranging from 1 to less than 1000 nanometers priorto incorporation into the coating composition. In another embodiment,the present invention is directed to cured compositions as previouslydescribed wherein the particles have an average particle size rangingfrom 1 to 100 nanometers prior to incorporation into the coatingcomposition.

In another embodiment, the present invention is directed to curedcompositions as previously described wherein the particles have anaverage particle size ranging from 5 to 50 nanometers prior toincorporation into the composition. In another embodiment, the presentinvention is directed to cured compositions as previously describedwherein the particles have an average particle size ranging from 5 to 25nanometers prior to incorporation into the composition. The particlesize may range between any combination of these values inclusive of therecited values.

In an embodiment where the average particle size of the particles isgreater than one micron, the average particle size can be measuredaccording to known laser scattering techniques. For example the averageparticle size of such particles is measured using a Horiba Model LA 900laser diffraction particle size instrument, which uses a helium-neonlaser with a wave length of 633 nm to measure the size of the particlesand assumes the particle has a spherical shape, i.e., the “particlesize” refers to the smallest sphere that will completely enclose theparticle.

In an embodiment of the present invention wherein the size of theparticles is less than or equal to one micron, the average particle sizecan be determined by visually examining an electron micrograph of atransmission electron microscopy (“TEM”) image, measuring the diameterof the particles in the image, and calculating the average particle sizebased on the magnification of the TEM image. One of ordinary skill inthe art will understand how to prepare such a TEM image, and adescription of one such method is disclosed in the examples set forthbelow. In one nonlimiting embodiment of the present invention, a TEMimage with 105,000× magnification is produced, and a conversion factoris obtained by dividing the magnification by 1000. Upon visualinspection, the diameter of the particles is measured in millimeters,and the measurement is converted to nanometers using the conversionfactor. The diameter of the particle refers to the smallest diametersphere that will completely enclose the particle.

The shape (or morphology) of the particles can vary depending upon thespecific embodiment of the present invention and its intendedapplication. For example generally spherical morphologies (such as solidbeads, microbeads, or hollow spheres), can be used, as well as particlesthat are cubic, platy, or acicular (elongated or fibrous). Additionally,the particles can have an internal structure that is hollow, porous orvoid free, or a combination of any of the foregoing, e.g., a hollowcenter with porous or solid walls. For more information on suitableparticle characteristics see H. Katz et al. (Ed.), Handbook of Fillersand Plastics (1987) at pages 9–10, which are specifically incorporatedby reference herein.

It will be recognized by one skilled in the art that mixtures of one ormore particles having different average particle sizes can beincorporated into the compositions in accordance with the presentinvention to impart the desired properties and characteristics to thecompositions. For example particles of varying particle sizes can beused in the compositions according to the present invention.

In one embodiment, the present invention is directed to compositions aspreviously described wherein the particles, when added to the othercomponents which form the composition, are present in the composition inan amount ranging from 0.01 to 75 weight percent based on total weightof the resin solids of the components which form the composition. Inanother embodiment, the present invention is directed to compositions aspreviously described wherein the particles, when added to the othercomponents which form the composition, are generally present in thecomposition in an amount of at least 0.1 weight percent, can be presentin the composition in an amount of at least 0.5 weight percent, and alsocan be present in the composition in an amount greater than 5 weightpercent based on total weight of the resin solids of the componentswhich form the composition.

In yet another embodiment, the present invention is directed to curedcompositions as previously described wherein, the particles, when addedto the other components which form the composition, are present in thecomposition in an amount less than 75 weight percent based on totalweight of the resin solids of the components which form the composition.In a further embodiment, the present invention is directed tocompositions as previously described wherein the particles, when addedto the other components which form the composition, are present in thecomposition in an amount less than 50 weight percent based on totalweight of the resin solids of the components which form the composition.In another embodiment, the present invention is directed to compositionsas previously described wherein the particles, when added to the othercomponents which form the composition, are present in the composition inan amount less than 20 weight percent based on total weight of the resinsolids of the components which form the composition. In anotherembodiment, the present invention is directed to compositions aspreviously described wherein the particles, when added to the othercomponents which form the composition, are present in the composition inan amount less than 10 weight percent based on total weight of the resinsolids of the components which form the composition. The weight percentof particles can range between any combination of these values inclusiveof the recited ranges

Additionally, in another embodiment, the present invention is directedto compositions wherein at least one surface active agent can be presentduring the formation of the compositions as previously described. The atleast one surface active agent can be selected from anionic, nonionic,and cationic surface active agents.

As used herein, by “surface active agent” is meant any material whichtends to lower the solid surface tension or surface energy of the curedcomposition or coating. That is, the cured composition or coating formedfrom a composition comprising a surface active agent has a lower solidsurface tension or surface energy than a cured coating formed from theanalogous composition which does not contain the surface active agent.

For purposes of the present invention, solid surface tension can bemeasured according to the Owens-Wendt method using a Rame'-Hart ContactAngle Goniometer with distilled water and methylene iodide as reagents.Generally, a 0.02 cc drop of one reagent is placed upon the curedcoating surface and the contact angle and its complement are measuredusing a standard microscope equipped with the goniometer. The contactangle and its complement are measured for each of three drops. Theprocess is then repeated using the other reagent. An average value iscalculated for the six measurements for each of the reagents. The solidsurface tension is then calculated using the Owens-Wendt equation:{γl(1+cos Φ)}/2=(γl^(d)γ_(s) ^(d))^(1/2)+(γl^(p)γ_(s) ^(p))^(1/2)

where γl is the surface tension of the liquid (methylene iodide=50.8,distilled water=72.8) and γ^(d) and γ^(p) are the dispersion and polarcomponents (methylene iodide γ^(d)=49.5, γ^(p)=1.3; distilled waterγ^(d)=21.8, γ^(p)=51.0); the values for Φ measured and the cos Φdetermined. Two equations are then setup, one for methylene iodide andone for water. The only unknowns are γ_(s) ^(d) and γ_(s) ^(p). The twoequations are then solved for the two unknowns. The two componentscombined represent the total solid surface tension.

The at least one surface active agent can be selected from amphiphilic,reactive functional group-containing polysiloxanes, amphiphilicfluoropolymers, and mixtures of any of the foregoing. With reference towater-soluble or water-dispersible amphiphilic materials, the term“amphiphilic” means a polymer having a generally hydrophilic polar endand a water-insoluble generally hydrophobic end. Nonlimiting examples ofsuitable functional group-containing polysiloxanes for use as surfaceactive agents include those polysiloxanes described below. Nonlimitingexamples of suitable amphiphilic fluoropolymers includefluoroethylene-alkyl vinyl ether alternating copolymers (such as thosedescribed in U.S. Pat. No. 4,345,057) available from Asahi Glass Companyunder the tradename LUMIFLON; fluorosurfactants, such as thefluoroaliphatic polymeric esters commercially available from 3M of St.Paul, Minn. under the tradename FLUORAD; functionalized perfluorinatedmaterials, such as 1H, 1H-perfluoro-nonanol commercially available fromFluoroChem USA; and perfluorinated(meth)acrylate resins, such as 1H, 1H,2H-perfluro-octyl methacrylate available from FluoroChem USA.

Nonlimiting examples of other surface active agents suitable for use inthe cured composition or coating of the present invention can includeanionic, nonionic and cationic surface active agents. Nonlimitingexamples of suitable anionic surface active agents include sulfates orsulfonates. Specific nonlimiting examples include higher alkylmononuclear aromatic sulfonates such as the higher alkyl benzenesulfonates containing from 10 to 16 carbon atoms in the alkyl group anda straight- or branched-chain, e.g., the sodium salts of decyl, undecyl,dodecyl, tridecyl, tetradecyl, pentadecyl or hexadecyl benzene sulfonateand the higher alkyl toluene, xylene and phenol sulfonates; alkylnaphthalene sulfonate, and sodium dinonyl naphthalene sulfonate. Othernonlimiting examples of suitable anionic surface active agents includeolefin sulfonates, including long chain alkenylene sulfonates, longchain hydroxyalkane sulfonates, and mixtures of any of the foregoing.Nonlimiting examples of other sulfate or sulfonate detergents areparaffin sulfonates such as the reaction products of alpha olefins andbisulfites (e.g., sodium bisulfite). Also comprised are sulfates ofhigher alcohols, such as sodium lauryl sulfate, sodium tallow alcoholsulfate, or sulfates of mono-or di-glycerides of fatty acids (e.g.,stearic monoglyceride monosulfate), alkyl poly(ethoxy)ether sulfatesincluding, but not limited to, the sulfates of the condensation productsof ethylene oxide and lauryl alcohol (usually having 1–5 ethenoxy groupsper molecule); lauryl or other higher alkyl glyceryl ether sulfonates;aromatic poly(ethenoxy)ether sulfates including, but not limited to, thesulfates of the condensation products of ethylene oxide and nonyl phenol(usually having 1–20 oxyethylene groups per molecule).

Further nonlimiting examples include salts of sulfated aliphaticalcohol, alkyl ether sulfate and/or alkyl aryl ethoxy sulfate availablefrom Rhone-Poulenc under the general tradename ABEX. Phosphate mono-ordi-ester type anionic surface active agents also can be used. Theseanionic surface active agents are well known in the art and arecommercially available under the general trademark GAFAC from GAFCorporation and under the general trademark TRITON from Rohm & HaasCompany.

Nonlimiting examples of nonionic surface active agents suitable for usein the cured composition or coating of the present invention includethose containing ether linkages and which are represented by thefollowing general formula: RO(R′O)_(n)H; wherein the substituent group Rrepresents a hydrocarbon group containing 6 to 60 carbon atoms, thesubstituent group R′ represents an alkylene group containing 2 or 3carbon atoms, and mixtures of any of the foregoing, and n is an integerranging from 2 to 100.

Such nonionic surface active agents can be prepared by treating fattyalcohols or alkyl-substituted phenols with an excess of ethylene orpropylene oxide. The alkyl carbon chain may contain from 14 to 40 carbonatoms and may be derived from a long chain fatty alcohol such as oleylalcohol or stearyl alcohol. Nonionic polyoxyethylene surface activeagents of the type represented by the formula above are commerciallyavailable under the general trade designation SURFYNOL from Air ProductsChemicals, Inc.; PLURONIC or TETRONIC from BASF Corporation; TERGITOLfrom Union Carbide; and SURFONIC from Huntsman Corporation. Othernonlimiting examples of suitable nonionic surface active agents includeblock copolymers of ethylene oxide and propylene oxide based on a glycolsuch as ethylene glycol or propylene glycol including, but not limitedto, those available from BASF Corporation under the general tradedesignation PLURONIC.

As indicated above, cationic surface active agents also can be used.Nonlimiting examples of cationic surface active agents suitable for usein the cured compositions or coatings of the present invention includeacid salts of alkyl amines such as ARMAC HT, an acetic acid salt ofn-alkyl amine available from Akzo Nobel Chemicals; imidazolinederivatives such as CALGENE C-100 available from Calgene Chemicals Inc.;ethoxylated amines or amides such as DETHOX Amine C-5, a cocoamineethoxylate available from Deforest Enterprises; ethoxylated fatty aminessuch as ETHOX TAM available from Ethox Chemicals, Inc.; and glycerylesters such as LEXEMUL AR, a glyceryl stearate/stearaidoethyldiethylamine available from Inolex Chemical Co.

Other examples of suitable surface active agents can includepolyacrylates. Nonlimiting examples of suitable polyacrylates includehomopolymers and copolymers of acrylate monomers, for examplepolybutylacrylate and copolymers derived from acrylate monomers (such asethyl(meth)acrylate, 2-ethylhexylacrylate, butyl(meth)acrylate andisobutyl acrylate), and hydroxy ethyl(meth)acrylate and (meth)acrylicacid monomers. In one embodiment, the polyacrylate can have amino andhydroxy functionality. Suitable amino and hydroxyl functional acrylatesare disclosed in Example 26 below and in U.S. Pat. No. 6,013,733, whichis incorporated herein by reference. Another example of a useful aminoand hydroxyl functional copolymer is a copolymer of hydroxy ethylacrylate, 2-ethylhexylacrylate, isobutyl acrylate and dimethylaminoethylmethacrylate. In another embodiment, the polyacrylate can have acidfunctionality, which can be provided, for example, by including acidfunctional monomers such as (meth)acrylic acid in the components used toprepare the polyacrylate. In another embodiment, the polyacrylate canhave acid functionality and hydroxyl functionality, which can beprovided, for example, by including acid functional monomers such as(meth)acrylic acid and hydroxyl functional monomers such as hydroxyethyl(meth)acrylate in the components used to prepare the polyacrylate.

In one embodiment, the components from which the coating composition isformed further can comprise at least one material which is curable byionizing radiation and/or actinic radiation. In another embodiment, theat least one hydroxyl functional non-vinyl material or polysiloxanediscussed above can contain radiation curable groups.

As used herein, “ionizing radiation” means high energy radiation and/orthe secondary energies resulting from conversion of this electron orother particle energy to neutron or gamma radiation, said energies beingat least 30,000 electron volts and can range from 50,000 to 300,000electron volts. While various types of ionizing irradiation are suitablefor this purpose, such as X-ray, gamma and beta rays, the radiationproduced by accelerated high energy electrons or electron beam devicesis preferred. The amount of ionizing radiation in rads for curingcompositions according to the present invention can vary based upon sucha factors as the components of the coating formulation, the thickness ofthe coating upon the substrate, the temperature of the coatingcomposition and the like. Generally, a 1 mil (25 micrometer) thick wetfilm of a coating composition according to the present invention can becured in the presence of oxygen through its thickness to a tack-freestate upon exposure to from 0.5 to 5 megarads of ionizing radiation.

“Actinic radiation” is light with wavelengths of electromagneticradiation ranging from the ultraviolet (“UV”) light range, through thevisible light range, and into the infrared range. Actinic radiationwhich can be used to cure coating compositions of the present inventiongenerally has wavelengths of electromagnetic radiation generally rangingfrom 150 to 2,000 nanometers (nm), can range from 180 to 1,000 nm, andtypically ranges from 200 to 500 nm. In one embodiment, ultravioletradiation having a wavelength ranging from 10 to 390 nm can be used.Examples of suitable ultraviolet light sources include mercury arcs,carbon arcs, low, medium or high pressure mercury lamps, swirl-flowplasma arcs and ultraviolet light emitting diodes. Preferred ultravioletlight-emitting lamps are medium pressure mercury vapor lamps havingoutputs ranging from 200 to 600 watts per inch (79 to 237 watts percentimeter) across the length of the lamp tube. Generally, a 1 mil (25micrometer) thick wet film of a coating composition according to thepresent invention can be cured through its thickness to a tack-freestate upon exposure to actinic radiation by passing the film at a rateof 20 to 1000 feet per minute (6 to 300 meters per minute) under fourmedium pressure mercury vapor lamps of exposure at 200 to 1000millijoules per square centimeter of the wet film.

The at least one radiation curable reactive functional group can beselected from vinyl groups, epoxy groups, maleimide groups, fumarategroups and combinations of the foregoing. Suitable first materialshaving vinyl functionality include those comprising unsaturated estergroups, vinyl ether groups, and vinyl esters as discussed below.

Suitable materials comprising unsaturated ester groups include materialscomprising acrylate groups, methacrylate groups and/or ethacrylategroups. In one embodiment, the unsaturated ester group is an acrylategroup. Useful materials comprising unsaturated ester groups includeesters and amides of acrylic or methacrylic acid or comonomers of suchan ester with another copolymerizable monomer. Suitable esters includemethyl (meth)acrylate, ethyl(meth)acrylate, isopropyl(meth)acrylate,n-butyl(meth)acrylate, isobutyl(meth)acrylate,2-ethylhexyl(meth)acrylate, 2-hydroxyethyl(meth)acrylate,glycidyl(meth)acrylate, ethylene glycol di(meth)acrylate, diethyleneglycol(meth)acrylate, tetraethylene glycol di(meth)acrylate, glyceroldi(meth)acrylate, glycerol tri(meth)acrylate, 1,3-propylene glycoldi(meth)acrylate, dipropylene glycol di(meth)acrylate, 1,4-butanedioldi(meth)acrylate, 1,2,4-butanetriol tri(meth)acrylate, 1,6-hexanedioldi(meth)acrylate, 1,4-cyclohexanediol di(meth)acrylate, 1,4-benzenedioldi(meth)acrylate, pentaerythritol tetra(meth)acrylate, 1,5-pentanedioldi(meth)acrylate, trimethylolpropane di(meth)acrylate,trimethylolpropane tri(meth)acrylate,2,2-dimethyl-3-hydroxypropyl-2,2-dimethyl-3-hydroxypropionate,isobornyl(meth)acrylate, tetrahydrofurfuryl(meth)acrylate,(meth)acrylates derived from aromatic glycidyl ethers such as bisphenolA diglycidyl ethers and aliphatic diglycidyl ethers, acrylic ormethacrylic amides such as (meth)acrylamide, diacetone(meth)acrylamide,N-(betahydroxyethyl) (meth)acrylamide,N,N-bis(betahydroxyethyl)(meth)acrylamide, methylenebis(meth)acrylamide, 1,6-hexamethylene bis(meth)acrylamide,diethylenetriamine tris(meth)acrylamide,bis(gamma-(meth)acrylamidepropoxy) ethane, beta-(meth)acrylamideethylacrylate and mixtures of the foregoing.

Other useful materials comprising unsaturated ester groups includehydroxy functional unsaturated polycarboxylates and polycaprolactones.Suitable hydroxy functional unsaturated polycarboxylates can be formedfrom ethylenically unsaturated carboxylic acids and polyhydric alcohols.Useful ethylenically unsaturated carboxylic acids have an acidfunctionality of at least two and/or their corresponding anhydrides.Non-limiting examples of ethylenically unsaturated carboxylic acids andanhydrides include maleic acid, maleic anhydride, fumaric acid, itaconicacid and mixtures of the foregoing. The unsaturated carboxylic acids canbe blended with saturated carboxylic acids, such as phthalic acid,isophthalic acid, terephthalic acid, trimellitic acid,tetrahydrophthalic acid, hexahydrophthalic acid, tetrachlorophthalicacid, adipic acid, azelaic acid, sebacic acid, succinic acid, glutaricacid, malonic acid, pimelic acid, suberic acid, 2,2-dimethylsuccinicacid, 2,2-dimethylglutaric acid, 3,3-dimethylglutaric acid, anhydridesof the foregoing, where they exist, and mixtures of any of theforegoing.

Useful polyhydric alcohols for preparing the hydroxy functionalunsaturated polycarboxylate include diethylene glycol, ethylene glycol,propylene glycol, dipropylene glycol, butylene glycol, glycerol,trimethylolpropane, pentaerythritol, sorbitol, 1,6-hexanediol,1,4-cyclohexanediol, 1,4-cyclohexanedimethanol,1,2-bis(hydroxyethyl)cyclohexane,2,2-dimethyl-3-hydroxypropyl-2,2-dimethyl-3-hydroxypropionate, neopentylglycol, 2-methyl-1,3-propane diol and mixtures of the foregoing.Monofunctional alcohols, such as C₁–C₁₅ monoalcohols, can be blendedwith the polyhydric alcohols, as desired.

The number average molecular weight of the unsaturated ester materialcan range from 500 to 50,000, as measured using gel permeationchromatography using a polystyrene standard. The unsaturated estermaterial can be prepared by any method well known to those skilled inthe art, such as by mixing the components and heating at temperaturesranging from 150° C. to 250° C. for 1 to 10 hours and removing waterformed during the esterification reaction. Conventional esterificationcatalysts, such as paratoluenesulfonic acid, butylstannoic acid,dibutyltin oxide, stannous fluoride and stannous octoate can be used toincrease the rate of reaction.

Vinyl ether functional materials suitable for use in the presentinvention include vinyl ethers prepared from di-, tri- ortetrafunctional polyols, acetylene and a basic catalyst under pressurein a manner well know to those skilled in the art. Also, vinylterminated polyesters such as those disclosed in U.S. Pat. No.5,286,835, which is incorporated herein by reference, can be used.Non-limiting examples of useful vinyl ether functional materials includetripropylene glycol, divinyl ether, diethylene glycol divinyl ether,1,4-butanediol divinyl ether, tetraethylene glycol divinyl ether,triethylene glycol divinyl ether, trimethylolpropane trivinyl ether,polytetrahydrofuran divinyl ether, vinyl ether terminated polyesters andmixtures of any of the foregoing. Also useful are unsaturated estermaterials having vinyl ether functionality and urethane vinyl ethermaterials, such as are disclosed in U.S. Pat. No. 5,942,556, which isincorporated herein by reference.

Other useful materials comprising epoxy functional groups include epoxyfunctional monomers such as glycidyl methacrylate and polymerscomprising at least two epoxide or oxirane groups per molecule such asare discussed above.

In another embodiment in which the coating is cured by actinic radiationor the combination of actinic radiation and thermal energy, thecomponents from which the coating composition are formed further cancomprise at least one photoinitiator or photosensitizer which providesfree radicals or cations to initiate the polymerization process. Usefulphotoinitiators have an adsorption in the range of 150 to 2,000 nm.Non-limiting examples of useful photoinitiators include benzoin,benzophenone, hydroxy benzophenone, anthraquinone, thioxanthone,substituted benzoins such as butyl isomers of benzoin ethers,α,α-diethoxyacetophenone, α,α-dimethoxy-α-phenylacetophenone,2-hydroxy-2-methyl-1-phenyl propane 1-one, 2,4,6-trimethyl benzoyldiphenyl phosphine oxide and mixtures of the foregoing. In oneembodiment, the photoinitiator is a 50:50 blend of2-hydroxy-2-methyl-1-phenyl propan-1-one, 2,4,6-trimethyl benzoyldiphenyl phosphine oxide such as DAROCURE 4265 which is commerciallyavailable from Ciba-Geigy Corporation.

The coating compositions of the present invention can be solvent-basedcoating compositions, water-based coating compositions, in solidparticulate form, that is, a powder coating composition, or in the formof a powder slurry or aqueous dispersion. The components of the presentinvention used to form the cured compositions of the present inventioncan be dissolved or dispersed in an organic solvent. Nonlimitingexamples of suitable organic solvents include alcohols, such as butanol;ketones, such as methyl amyl ketone; aromatic hydrocarbons, such asxylene; and glycol ethers, such as, ethylene glycol monobutyl ether;esters; other solvents; and mixtures of any of the foregoing.

In solvent based compositions, the organic solvent is generally presentin amounts ranging from 5 to 80 percent by weight based on total weightof the resin solids of the components which form the composition, andcan be present in an amount ranging from 30 to 50 percent by weight. Thecompositions as described above can have a total solids content rangingfrom 40 to 75 percent by weight based on total weight of the resinsolids of the components which form the composition, and can have atotal solids content ranging from 50 to 70 percent by weight.Alternatively, the inventive compositions can be in solid particulateform suitable for use as a powder coating, or suitable for dispersion ina liquid medium such as water for use as a powder slurry.

In a further embodiment, a catalyst can be present during the coatingcomposition's formation. Nonlimiting examples of suitable catalystsinclude acidic materials, for example acid phosphates, such as phenylacid phosphate, and substituted or unsubstituted sulfonic acids such asdodecylbenzene sulfonic acid or para-toluene sulfonic acid and othercatalysts such as amine and tin catalysts. The catalyst can be present,when added to the other components which form the coating composition,in an amount ranging from 0.1 to 5.0 percent by weight based on thetotal weight of the resin solids of the components which form thecoating composition.

In another embodiment, additional components can be present during theformation of the coating compositions as previously described. Theseadditional components include, but are not limited to, flexibilizers,plasticizers, surface active agents as defined herein (such as, forexample polysiloxanes), thixotropic agents, anti-gassing agents, organiccosolvents, flow controllers, anti-oxidants, UV light absorbers,coloring agents or tints, and similar additives conventional in the art,as well as mixtures of any of the foregoing can be included in thecoating composition. These additional ingredients can present, whenadded to the other components which form the coating composition, in anamount up to 40 percent by weight based on the total weight of the resinsolids of the components which form the coating composition.

In a further embodiment of the present invention, the surface region ofthe cured composition is essentially free of silicone fluid. As usedherein, “essentially free” means less than 10% by weight, and can beless than 5% by weight, based on the total weight of the resin solidswhich form the cured composition. In a further embodiment, the curedcomposition is free of silicone fluid.

The amount of the coating composition applied to the substrate can varybased upon such factors as the type of substrate and intended use of thesubstrate, i.e., the environment in which the substrate is to be placedand the nature of the contacting materials.

In yet another embodiment, the present invention is directed to a coatedsubstrate comprising a substrate and a coating composition coated overat least a portion of the substrate, wherein the coating composition isselected from any of the foregoing coating compositions. In stillanother embodiment, the present is directed to a method of coating asubstrate which comprises applying a coating composition over at least aportion of the substrate, wherein the coating composition is selectedfrom any of the foregoing coating compositions.

In another embodiment, the present invention is directed to a method ofcoating a substrate further comprising a step of curing the coatingcomposition after application to the substrate. The components used toform the coating compositions in these embodiments can be selected fromthe components discussed above, and additional components also can beselected from those recited above.

As used herein, a composition “over at least a portion of a substrate”refers to a composition directly applied to at least a portion of thesubstrate, as well as a composition applied to any coating materialwhich was previously applied to at least a portion of the substrate.

The coating compositions of the present invention can be applied overvirtually any substrate including wood, metals, glass, cloth, plastic,foam, polymeric substrates such as elastomeric substrates, and the like.In one embodiment, the present invention is directed to a coatedsubstrate as previously described wherein the coated substrate is aflexible substrate. In another embodiment, the present invention isdirected to a coated substrate as previously described wherein thecoated substrate is a rigid substrate.

In a further embodiment, the present invention is directed to coatedsubstrates as previously described wherein the coated substrate is aceramic substrate. In still another embodiment, the present invention isdirected to coated substrates as previously described wherein the coatedsubstrate is a polymeric substrate. In another embodiment, the presentinvention is directed to a coated metallic substrate comprising ametallic substrate and a cured composition coated over at least aportion of the metallic substrate, wherein the cured composition isselected from any of the foregoing compositions. The components used toform the cured compositions in these embodiments can be selected fromthe components discussed above, and additional components also can beselected from those recited above.

A further embodiment of the present invention is directed to a coatedautomobile substrate comprising an automobile substrate and a curedcomposition coated over at least a portion of the automobile substrate,wherein the cured composition is selected from any of the foregoingcompositions. In yet another embodiment, the present invention isdirected to a method of making a coated automobile substrate comprisingproviding an automobile substrate and applying over at least a portionof the automotive substrate a coating composition selected from any ofthe foregoing compositions. Again, the components used to form the curedcompositions in these embodiments can be selected from the componentsdiscussed above, and additional components also can be selected fromthose recited above.

Suitable flexible elastomeric substrates can include any of thethermoplastic or thermoset synthetic materials well known in the art.Nonlimiting examples of suitable flexible elastomeric substratematerials include polyethylene, polypropylene, thermoplastic polyolefin(“TPO”), reaction injected molded polyurethane (“RIM”), andthermoplastic polyurethane (“TPU”).

Nonlimiting examples of thermoset materials useful as substrates inconnection with the present invention include polyesters, epoxides,phenolics, polyurethanes such as “RIM” thermoset materials, and mixturesof any of the foregoing. Nonlimiting examples of suitable thermoplasticmaterials include thermoplastic polyolefins such as polyethylene,polypropylene, polyamides such as nylon, thermoplastic polyurethanes,thermoplastic polyesters, acrylic polymers, vinyl polymers,polycarbonates, acrylonitrile-butadiene-styrene (“ABS”) copolymers,ethylene propylene diene terpolymer (“EPDM”) rubber, copolymers, andmixtures of any of the foregoing.

Nonlimiting examples of suitable metal substrates include ferrous metals(e.g., iron, steel, and alloys thereof), nonferrous metals (e.g.,aluminum, zinc, magnesium, and alloys thereof), and mixtures of any ofthe foregoing. In the particular use of automobile components, thesubstrate can be formed from cold rolled steel, electrogalvanized steelsuch as hot dip electrogalvanized steel, electrogalvanized iron-zincsteel, aluminum, and magnesium.

When the substrates are used as components to fabricate automotivevehicles (including, but not limited to, automobiles, trucks andtractors) they can have any shape, and can be selected from the metallicand flexible substrates described above. Typical shapes of automotivebody components can include bodies (frames), hoods, doors, fenders,mirror housings, bumpers, and trim for automotive vehicles.

In a further embodiment, the present invention is directed to coatedautomotive substrates as previously described wherein the coatedautomotive substrate is a hood. In another embodiment, the presentinvention is directed to coated automotive substrates as previouslydescribed wherein the coated automotive substrate is a door. In anotherembodiment, the present invention is directed to coated automotivesubstrates as previously described wherein the coated automotivesubstrate is a fender. In another embodiment, the present invention isdirected to coated automotive substrates as previously described whereinthe coated automotive substrate is a quarterpanel. The components usedto form the cured compositions used to coat the automotive substrates inthese embodiments can be selected from the components discussed above.

In embodiments of the present invention directed to automotiveapplications, the cured compositions can be, for example, theelectrodeposition coating, the primer coating, the basecoat, and/or thetopcoat. Suitable topcoats include monocoats and basecoat/clearcoatcomposites. Monocoats are formed from one or more layers of a coloredcoating composition. Basecoat/clearcoat composites comprise one or morelayers of a colored basecoat composition, and one or more layers of aclearcoating composition, wherein the basecoat composition has at leastone component which is different from the clearcoat composition. In theembodiments of the present invention directed to automotiveapplications, the clearcoat can be transparent after, application.

In another embodiment, the present invention is directed tomulti-component composite cured compositions comprising a basecoatdeposited from a pigmented coating composition, and a topcoatingcomposition applied over the basecoat, wherein the topcoatingcomposition is selected from any of the compositions previouslydescribed.

In one embodiment, the present invention is directed to amulti-component composite cured composition as previously described,wherein the topcoating composition is transparent after curing and isselected from any of the cured compositions previously described. Thecomponents used to form the topcoating composition in these embodimentscan be selected from the coating components discussed above, andadditional components also can be selected from those recited above.

The basecoat and transparent topcoat (i.e., clearcoat) compositions usedin the multi-component composite cured compositions of the presentinvention in certain instances can be formulated into liquid high solidscompositions, that is, compositions containing 40 percent, or greaterthan 50 percent by weight resin solids. The solids content can bedetermined by heating a sample of the cured composition to 105° C. to110° C. for 1–2 hours to drive off the volatile material, andsubsequently measuring relative weight loss. As aforementioned, althoughthe cured compositions can be formed from liquid coating compositions,they also can be formed from coating compositions formulated as powdercoating compositions.

The coating composition of the basecoat in the color-plus-clear systemcan be any of the compositions useful in coatings applications,particularly automotive applications. The coating composition of thebasecoat can be formed from components comprising a resinous binder anda pigment to act as the colorant. Nonlimiting examples of resinousbinders are acrylic polymers, polyesters, alkyds, and polyurethanes.

The resinous binders for the basecoat can be organic solvent-basedmaterials such as those described in U.S. Pat. No. 4,220,679, notecolumn 2, line 24 continuing through column 4, line 40, which portionsis incorporated by reference. Also, water-based coating compositionssuch as those described in U.S. Pat. Nos. 4,403,003, 4,147,679 and5,071,904 can be used as the binder in the basecoat composition. TheseU.S. patents are incorporated herein by reference.

The basecoat composition can comprise one or more pigments as colorants.Nonlimiting examples of suitable metallic pigments include aluminumflake, copper bronze flake, and metal oxide coated mica.

Besides the metallic pigments, the basecoat compositions can containnonmetallic color pigments conventionally used in surface coatings suchas, for example inorganic pigments such as titanium dioxide, iron oxide,chromium oxide, lead chromate, and carbon black; and organic pigmentssuch as phthalocyanine blue and phthalocyanine green.

Optional ingredients in the basecoat composition can comprise thosewhich are well known in the art of formulating surface coatings and cancomprise surface active agents, flow control agents, thixotropic agents,fillers, anti-gassing agents, organic co-solvents, catalysts, and othercustomary auxiliaries. Nonlimiting examples of these materials andsuitable amounts are described in U.S. Pat. Nos. 4,220,679; 4,403,003;4,147,769; and 5,071,904, which are incorporated herein by reference.

The basecoat compositions can be applied to the substrate by anyconventional coating technique such as brushing, spraying, dipping, orflowing. Spray techniques and equipment for air spraying, airless spray,and electrostatic spraying in either manual or automatic methods, knownin the art can be used.

During application of the basecoat to the substrate, the film thicknessof the basecoat formed on the substrate can range from 0.1 to 5 mils. Inanother embodiment, the film thickness of the basecoat formed on thesubstrate can range 0.1 to 1 mils, and can be 0.4 mils.

After forming a film of the basecoat on the substrate, the basecoat canbe cured or alternatively given a drying step in which solvent is drivenout of the basecoat film by heating or an air drying period beforeapplication of the clearcoat. Suitable drying conditions may depend onthe particular basecoat composition, and on the ambient humidity if thecomposition is water-borne, but a drying time from 1 to 15 minutes at atemperature of 75° to 200° F. can be adequate.

The transparent or clear topcoat composition can be applied to thebasecoat by any conventional coating technique, including, but notlimited to, compressed air spraying, electrostatic spraying, and eithermanual or automatic methods. The transparent topcoat can be applied to acured or to a dried basecoat before the basecoat has been cured. In thelatter instance, the two coatings can then be heated to cure bothcoating layers simultaneously. The clearcoating thickness (dry filmthickness) can be 1 to 6 mils.

The coating composition is cured by the combination of ionizing oractinic radiation and thermal energy as described in detail above.Typical radiation energy curing conditions are discussed in detailabove. Typical thermal energy curing conditions can range from 50° F. to475° F. (10° C. to 246° F.) for 1 to 30 minutes.

A second topcoat coating composition can be applied to the first topcoatto form a “clear-on-clear” topcoat. The first topcoat coatingcomposition can be applied over the basecoat as described above. Thesecond topcoat coating composition can be applied to a cured or to adried first topcoat before the basecoat and first topcoat have beencured. The basecoat, the first topcoat, and the second topcoat can thenbe heated to cure the three coatings simultaneously.

It should be understood that the second transparent topcoat and thefirst transparent topcoat coating compositions can be the same ordifferent provided that, when applied wet-on-wet, one topcoat does notsubstantially interfere with the curing of the other for example byinhibiting solvent/water evaporation from a lower layer. Moreover, thefirst topcoat, the second topcoat or both can be the cured compositionof the present invention. The first transparent topcoat composition canbe virtually any transparent topcoating composition known to thoseskilled in the art. The first transparent topcoat composition can bewater-borne or solventborne, or, alternatively, in solid particulateform, i.e., a powder coating.

Nonlimiting examples of suitable first topcoating compositions includecrosslinkable coating compositions comprising at least onethermosettable coating material and at least one curing agent. Suitablewaterborne clearcoats are disclosed in U.S. Pat. No. 5,098,947, whichpatent is incorporated herein by reference, and are based onwater-soluble acrylic resins. Useful solvent borne clearcoats aredisclosed in U.S. Pat. Nos. 5,196,485 and 5,814,410, which patents areincorporated herein by reference, and include polyepoxides and polyacidcuring agents. Suitable powder clearcoats are described in U.S. Pat. No.5,663,240, which is incorporated herein by reference, and include epoxyfunctional acrylic copolymers and polycarboxylic acid curing agents.

Typically, after forming the first topcoat over the basecoat, the firsttopcoat is given a drying step in which solvent is driven out of thefilm by heating or, alternatively, an air drying period or curing step,before the application of the second topcoat. Suitable drying conditionswill depend on the particular first topcoat composition, and on theambient humidity if the composition is water-borne, but, in general, adrying time from 1 to 15 minutes at a temperature of 750 to 200° F. willbe adequate.

The second topcoat coating composition of the present invention can beapplied as described above for the first topcoat by any conventionalcoating application technique. Curing conditions can be those describedabove for the topcoat. The second topcoating dry film thickness canrange from 0.1 to 3 mils (7.5 micrometers to 75 micrometers).

It should be mentioned that the coating compositions can beadvantageously formulated as a “monocoat,” that is a coating which formsessentially one coating layer when applied to a substrate. The monocoatcoating composition can be pigmented. Nonlimiting examples of suitablepigments include those mentioned above. When employed as a monocoat, thecoating compositions of the present invention can be applied (by any ofthe conventional application techniques discussed above) in two or moresuccessive coats, and, in certain instances can be applied with only anambient flash period between coats. The multi-coats when cured can formessentially one coating layer.

In another embodiment, the present invention is directed to a method formaking a multi-component composite comprising (a) applying a pigmentedcomposition to a substrate to form a basecoat; and (b) applying atopcoating composition over at least a portion of the basecoat to form atopcoat thereon, wherein the topcoating composition is selected from anyof the compositions described above. The components used to form thetopcoating composition in this embodiment can be selected from thecoating components discussed above, and additional components also canbe selected from those recited above.

The coatings formed from the cured compositions according to the presentinvention can have outstanding appearance properties and initial scratch(mar) resistance properties, as well as post-weathering or “retained”scratch (mar) resistance, which can be evaluated by measuring the glossof coated substrates before and after abrading of the coated substrates.

The initial 20° gloss of a coated substrate according to the presentinvention can be measured with a 20° NOVO-GLOSS 20 statisticalglossmeter, available from Gardner Instrument Company, Inc. The coatedsubstrate can be subjected to scratch testing by linearly scratching thecoating or substrate with a weighted abrasive paper for ten double rubsusing an Atlas AATCC Scratch Tester, Model CM-5, available from AtlasElectrical Devices Company of Chicago, Ill. The abrasive paper is 3M 281Q WETORDRY™ PRODUCTION™ 9 micron polishing paper sheets, which arecommercially available from 3M Company of St. Paul, Minn. Panels arethen rinsed with tap water and carefully patted dry with a paper towel.The 20° gloss is measured on the scratched area of each test panel. Thenumber reported is the percent of the initial gloss retained afterscratch testing, i.e., 100%× scratched gloss/initial gloss. This testmethod is fully disclosed in the examples that follow.

In one embodiment, the present invention is directed to curedcompositions having an initial 20° gloss (as measured using a 20°NOVO-GLOSS 20 statistical glossmeter, available from Gardner InstrumentCompany described above) of greater than 40, the compositions being anyof the foregoing compositions according to the present invention. Inanother embodiment, the present invention is directed to curedcompositions having an initial 20° gloss (as measured using a 20°NOVO-GLOSS 20 statistical glossmeter, available from Gardner InstrumentCompany described above) of greater than 50, or of greater than 70, thecompositions being any of the foregoing compositions according to thepresent invention.

Moreover, in another embodiment, the present invention is directed tocured compositions having a post-weathering or “retained” scratchresistance value such that after scratch testing, greater than 30percent of initial 20° gloss is retained. Moreover, the curedcompositions of the present invention can have a post-weathering scratchresistance (as measured using the scratch test method described aboveafter the unscratched test panels were subjected to simulated weatheringby QUV exposure to UVA-340 bulbs in a weathering cabinet available fromQ Panel Company) such that greater than 40 percent of initial 20° glossis retained is retained after weathering. In another embodiment, thepresent invention is directed to cured compositions having a retainedscratch resistance value such that after scratch testing greater than 60percent of initial 20° gloss is retained.

In one embodiment, the present invention is directed to methods ofimproving the scratch resistance of a substrate comprising applying tothe substrate any of the inventive compositions described for thesubstrate. In another embodiment, the present invention is directed to amethod of improving the dirt repellency of a substrate comprisingapplying to the comprising any of the inventive compositions describedfor the substrate.

In another embodiment, the present invention is directed to a method forretaining the gloss of a substrate over time comprising applying to thesubstrate comprising any of the inventive compositions described for thesubstrate. In another embodiment, the present invention is directed to amethod for revitalizing the gloss of a substrate comprising applying tothe substrate any of the inventive compositions described for thesubstrate.

In another embodiment, the cured compositions of the present inventionalso can be useful as decorative or protective coatings for pigmentedplastic (elastomeric) substrates, such as those described above, ormold-in-color (“MIC”) plastic substrates. In these applications, thecompositions can be applied directly to the plastic substrate orincluded in the molding matrix. Optionally, an adhesion promoter canfirst be applied directly to the plastic or elastomeric substrate andthe composition applied as a topcoat thereover. The compositions of thepresent invention also can be advantageously formulated as pigmentedcoating compositions for use as primer coatings, as basecoats inmulti-component composite coatings, and as monocoat topcoats includingpigments or colorants. The components used to form the compositions inthese embodiments can be selected from the coating components discussedabove, and additional components also can be selected from those recitedabove.

In yet another embodiment of the present invention, a cured compositionis provided which comprises particles dispersed in a cured compositioncomprising one or more thermoplastic materials. As previously described,the concentration of particles is greater in the surface region than inthe bulk region. The cured composition can be derived from athermoplastic resinous coating composition. Nonlimiting examples ofsuitable thermoplastic materials include high molecular weight (i.e., Mwgreater than 20,000, greater than 40,000, or greater than 60,000),acrylic polymers, polyolefin polymers, polyamide polymers, and polyesterpolymers suitable for use in lacquer dry systems. One nonlimitingexample of a class of thermoplastic materials from which the curedcomposition can be derived is fluoropolymer-acrylic copolymers such asthose prepared from polyvinylidene fluoride, for example KYNAR 500(available from Ausimont USA, Inc.) and thermoplastic acryliccopolymers, such as ACRYLOID B44 (65% methyl methacrylate and 35% ethylacrylate), available from Dock Resin, Inc.

The coating compositions of the present invention can provide goodrecoat or repair adhesion, as shown in the examples below.

Illustrating the invention is the following examples which, however, arenot to be considered as limiting the invention to their details. Unlessotherwise indicated, all parts and percentages in the followingexamples, as well as throughout the specification, are by weight.

EXAMPLE 1

Silylated compounds for use in the coating compositions disclosed belowwere prepared as follows:

Silylated Compound A

This example illustrates the preparation of a silylated compound that isa half-acid ester of methyl hexahydrophthalic anhydride andtrimethylolpropane with residual carboxyl groups reacted with propyleneoxide.

A reaction vessel equipped with stirrer, thermocouple, temperaturecontrol, pumps and fitted with valved ports was charged with 1202.9grams trimethylolpropane (commercially available from Bayer USA), 14.4grams of triphenyl phosphine (commercially available from Aldrich®),12.1 grams of triisooctyl phosphite (commercially available from GESpecialty Chemicals), and 800.0 grams of n-butyl acetate (commerciallyavailable from Union Carbide Chemicals and Plastics Co., Inc.).

The reactor was heated to 115° C. and 4436.7 grams ofmethylhexahydrophthalic anhydride (commercially available from MillikenChemical) were added over 90 minutes, and then held 4 hours at 115° C.1533.4 grams of propylene oxide (commercially available from FisherScientific Company) was charged to the reactor over 1 hour. The reactionwas held 4 hours until the acid value was less 5.38 mg KOH/gram.Residual propylene oxide was removed by vacuum distilling at 60 to 80 mmHg at 96° C. max. The resultant product had a total solids content of95.25%.

This product was silylated by the following procedure: 637.6 grams(95.25% solids) of the previously described material were charged to areaction flask equipped with an overhead stirrer, nitrogen inlet,thermocouple, addition funnel, and condenser. The temperature wasincreased to 110° C. for one hour with nitrogen sparge to ensure thatthe system was dry. The temperature was then decreased to 85° C. undernitrogen blanket, at which time 180.9 grams hexamethyldisilazane(commercially available from Aldrich®) were added drop-wise over a 30minute period. The reaction was allowed to continue one additional hour,at which time a nitrogen sparge was introduced. The reaction wasconsidered complete when the size of the IR peak corresponding to thehydroxyl moiety was negligible. The solution was allowed to continuestirring under nitrogen sparge at 85° C. until the ammonia (by-product)was removed. Theoretical resin solids content was 96.3%.

Silylated Compound B

This example illustrates the preparation of a silylated compound that isa half-acid ester of methyl hexahydrophthalic anhydride andtrimethylolpropane with residual carboxyl groups reacted with propyleneoxide.

A reaction vessel equipped with stirrer, thermocouple, temperaturecontrol, pumps and fitted with valved ports was charged with 550.0 gramstrimethylolpropane (commercially available from Bayer USA), 6.8 grams oftriphenyl phosphine (commercially available from Aldrich®), 5.57 gramsof triisooctyl phosphite (commercially available from GE SpecialtyChemicals), and 205.7 grams of n-butyl acetate (commercially availablefrom Union Carbide Chemicals and Plastics Co., Inc.). The reaction washeated to 115° C. 2030 grams of methylhexylhydrophthalic anhydride(commercially available from Milliken Chemical) was added over 90minutes. The reaction was held 4 hours at 115° C. The reactor was cooledto 100° C. and 769.9 grams of propylene oxide (commercially availablefrom Fisher Scientific Company) was added over 1 hour. The reaction washeld 5 hours at 100° C. until the acid value was 3.1 mg KOH/gram.Residual propylene oxide was removed by vacuum distilling at 60 to 80 mmHg at 70° C. The resultant product had a total solids content of 95.08%.The product was thinned to 80.0% solids with butyl acetate.

This product was silylated by the following procedure: 3449.3 grams(80.0% solids) of the previously described material were charged to areaction flask equipped with an overhead stirrer, nitrogen inlet,thermocouple, addition funnel, and condenser. The temperature wasincreased to 110° C. for one hour with nitrogen sparge to ensure thatthe system was dry. The temperature was then decreased to 85° C. undernitrogen blanket, at which time 821.9 grams hexamethyldisilazane(commercially available from Aldrich®) were added drop-wise over a onehour period. The reaction was allowed to continue 15 additional hours,at which time a nitrogen sparge was introduced. The reaction wasconsidered complete when the size of the IR peak corresponding to thehydroxyl moiety was negligible. The solution was allowed to continuestirring under nitrogen sparge at 85° C. until the ammonia (by-product)was removed.

Theoretical resin solids content was 96.3%.

A silica dispersion, polysiloxane polyol and composition pre-mixturesfor use in the coating compositions disclosed below were prepared asfollows:

Silica Dispersion

The colloidal silica dispersion was prepared as follows. A suitablereaction vessel equipped for vacuum distillation was flushed with N₂. Tothe reaction flask was added 3150 g of the polysiloxane polyol describedabove, 1350 g of ORGANOSILICASOLT™ MT-ST colloidal silica which iscommercially available from Nissan Chemicals and 1440 g of methyl amylketone. The mean particle size of the silica particles was 10–20nanometers, as disclosed at http//www.snowtex.com/organo_types.html(Jun. 2, 2000), which is incorporated by reference herein. The resultingmixture was vacuum distilled at 25° C. for a period of 8 hours.

Polysiloxane Polyol

The polysiloxane polyol was a product of the hydrosilylation of areactive silicone fluid with an approximate degree of polymerization of3 to 7, i.e., (Si—O)₃ to (Si—O)₇. The polysiloxane polyol was preparedfrom a proportionately scaled-up batch of the following mixture ofingredients in the ratios indicated:

Equivalent Parts By Weight Ingredients Weight Equivalents (kilograms)Charge I: Trimethylolpropane 174.0 756.0 131.54 monoallyl ether ChargeII: MASILWAX BASE¹ 156.7² 594.8 93.21 Charge III: Chloroplatinic acid 10ppm Toluene 0.23 Isopropanol 0.07 ¹Polysiloxane-containing siliconhydride, commercially available from BASF Corporation. ²Equivalentweight based on mercuric bichloride determination.

To a suitable reaction vessel equipped with a means for maintaining anitrogen blanket, Charge I and an amount of sodium bicarbonateequivalent to 20 to 25 ppm of total monomer solids was added at ambientconditions and the temperature was gradually increased to 75° C. under anitrogen blanket. At that temperature, 5.0% of Charge II was added underagitation, followed by the addition of Charge III, equivalent to 10 ppmof active platinum based on total monomer solids. The reaction was thenallowed to exotherm to 95° C. at which time the remainder of Charge IIwas added at a rate such that the temperature did not exceed 95° C.After completion of this addition, the reaction temperature wasmaintained at 95° C. and monitored by infrared spectroscopy fordisappearance of the silicon hydride absorption band (Si—H, 2150 cm⁻¹).

Composition Pre-Mixtures

The following pre-mixtures of selected components of the coatingcompositions discussed below were prepared by sequentially mixing eachof the components with agitation.

Parts by Ingredient weight (grams) Solid weights (grams) Pre-Mix 1:Methyl n-amyl ketone 18.0 — Butyl Cellosolve ® acetate¹ 18.0 — ButylCarbitol ® acetate² 4.0 — TINUVIN 384³ 1.58 1.50 TINUVIN 400⁴ 1.76 1.50TINUVIN 292⁵ 0.40 0.40 Silica Dispersion from above 13.2 10.0 RESIMENE757⁶ 27.1 26.3 LUWIPAL 018⁷ 11.9 8.7 ¹2-Butoxyethyl acetate solvent iscommercially available from Union Carbide Corp. ²2-(2-Butoxyethoxy)ethyl acetate is commercially available from Union Carbide Corp.³Substituted benzotriazole UV light stabilizer commercially availablefrom Ciba Specialty Chemicals Corp. ⁴Substituted triazine UV lightstabilizer commercially available from Ciba Specialty Chemicals Corp.⁵Sterically hindered amine light stabilizer commercially available fromCiba Specialty Chemicals Corp. ⁶Methylated and butylatedmelamine-formaldehyde resin available from Solutia Inc. ⁷High imino,butylated melamine formaldehyde resin commercially available from BASFCorp. Pre-Mix 2: Carbamoylated acrylic¹ 79.4 50.0 Carbamoylatedpolyeste² 69.4 50.0 ¹(58% butyl methacrylate/40% hydroxypropylacrylate/2% methyl styrene dimer) 64% solids in a solvent blend of (50%DOWANOL PM/50% propanoic acid, 3-ethoxy ethyl ester) 75% carbamoylatedwith methyl carbamate. ²(10.6% trimethylol propane/22.7%2,2,4-trimethyl-1,3-pentanediol/17.5% neopentyl glycol/49.2%hexahydrophthalic anhydride) 69% solids in a solvent blend of (44%DOWANOL PM/56% DOWANOL PM Acetate) 75% carbamoylated with methylcarbamate. Pre-Mix 3: Methyl n-amyl ketone 5.4 — Butyl Cellosolve ®acetate¹ 10.8 — Butyl Carbitol ® acetate² 1.8 — TINUVIN ® 928³ 3.00 3.00TINUVIN ® 292⁴ 0.40 0.40 TINUVIN ® 123⁵ 0.60 0.60 CYMEL ® 1130⁶ 29.929.9 RESIMENE ® 741⁷ 11.3 9.9 ¹2-Butoxyethyl acetate solvent iscommercially available from Union Carbide Corp. ²2-(2-Butoxyethoxy)ethyl acetate is commercially available from Union Carbide Corp.³2-(2H-Benzotriazol-2yl)-6-(1-methyl-1-phenylethyl)-4-(1,1,3,3-tetramethylbutyl)phenolUV absorber available from Ciba Specialty Chemicals Corp. ⁴Stericallyhindered amine light stabilizer commercially available from CibaSpecialty Chemicals Corp.⁵Bis-(1-octyloxy-2,2,6,6-tetramethyl-4-piperidinyl) sebacate hinderedaminoether light stabilizer available from Ciba Specialty ChemicalsCorp. ⁶Methylated and butylated melamine-formaldehyde resin availablefrom Cytec Industries, Inc. ⁷Methylated melamine-formaldehyde resinavailable from Solutia Inc. Pre-Mix 4: Methyl n-amyl ketone 7.5 — ButylCellosolve ® acetate¹ 15.0 — Butyl Carbitol ® acetate² 2.50 — TINUVIN ®928³ 3.00 3.00 TINUVIN ® 292⁴ 0.40 0.40 TINUVIN ® 123⁵ 0.60 0.60 SilicaDispersion from above 26.4 20.0 Polysiloxane polyol from 1.00 1.00 aboveCYMEL ® 1130⁶ 29.9 29.9. RESIMENE ® 741⁷ 11.3 9.9 ¹2-Butoxyethyl acetatesolvent is commercially available from Union Carbide Corp.²2-(2-Butoxyethoxy) ethyl acetate is commercially available from UnionCarbide Corp.³2-(2H-Benzotriazol-2yl)-6-(1-methyl-1-phenylethyl)-4-(1,1,3,3-tetramethylbutyl)phenolUV absorber available from Ciba Specialty Chemicals Corp. ⁴Stericallyhindered amine light stabilizer commercially available from CibaSpecialty Chemicals Corp.⁵Bis-(1-octyloxy-2,2,6,6-tetramethyl-4-piperidinyl) sebacate hinderedaminoether light stabilizer available from Ciba Specialty ChemicalsCorp. ⁶Methylated and butylated melamine-formaldehyde resin availablefrom Cytec Industries, Inc. ⁷Methylated melamine-formaldehyde resinavailable from Solutia Inc.

The pre-mixtures of ingredients from Pre-Mixes 1, 2, 3 and 4 were usedin Coating Compositions 1–12. The components for forming CoatingCompositions 1–12 are listed below in Tables 1–3. The amounts listed arethe total parts by weight in grams and the amount within parenthesis arepercentages by weight based on weight of resin solids. Each componentwas mixed sequentially with agitation.

TABLE 1 COATING COMPOSITION Ingredient 1 2 3 4 5 Pre-mix 1 95.9 (48.4)95.9 (48.4) — — — Pre-mix 2 86.3 (58.0) 57.4 (38.6) — — — Pre-mix 3 — —63.2 (43.8) 63.2 (43.8) 63.2 (43.8) Silica Dispersion from — — — 13.2(10.0) 26.4 (20.0) above Polysiloxane polyol from — — —  8.0 (8.0)   1.0(1.0)  above Silylated Compound A — 20.1 (19.4) 62.5 (60.2) 46.9 (45.2)46.9 (45.2) Multiflow¹ — — 0.60 (0.30) — — Polybutyl acrylate² 0.50(0.30) 0.50 (0.30) 0.67 (0.40) 0.67 (0.40) 0.67 (0.40) Blocked acidcatalyst³ 2.50 (1.00) 2.50 (1.00) — — — Acid catalyst⁴ — — 1.43 (1.00)1.43 (1.00) 1.43 (1.00) Reduction Information Methyl n-amyl ketone 3.49— 3.60 2.89 2.10 Butyl Cellosolve ® 3.49 — 7.2 5.8 4.20 acetate⁵ ButylCarbitol ® acetate⁶ 0.76 — 1.2 0.96 0.7 Spray viscosity⁷ (sec) 28 28 3738 38 Paint temperature (° F.) 73 73 72 72 72 230° F. (110° C.) %Solids⁸ 52 58 64 66 68 ¹50% solution of MODAFLOW ®, available fromSolutia Inc., supplied in xylene. MODAFLOW ® is a polymer made of 75% byweight 2-ethyl hexyl acrylate, 25% by weight ethyl acrylate with anumber average molecular weight of 7934. ²A flow control agent having aMw of 6700 and a Mn of 2600 made in xylene at 60% solids available fromDuPont. ³Dodecyl benzene sulfonic acid solution, blocked withdiisopropanol amine to 91% total neutralization, 40 percent acid solidsin ethanol. ⁴Dodecyl benzene sulfonic acid solution (70% solids inisopropanol) available from Chemcentral. ⁵2-Butoxyethyl acetate solventis commercially available from Union Carbide Corp. ⁶2-(2-Butoxyethoxy)ethyl acetate is commercially available from Union Carbide Corp.⁷Viscosity measured in seconds with a #4 FORD efflux cup at ambienttemperature. ⁸% Solids of a coating is determined by taking a specificquantity of the coating and adding it into a tarred aluminum dish andrecording the coating weight. Three milliliters of xylene is added intothe aluminum dish to dissolve and/or disperse the coating. The coatingis then heated in an oven for sixty minutes at 230° F. (110° C.). Afterremoval from the oven, the aluminum dish is cooled, re-weighed, and thenon-volatile content (weight percent solids) is calculated using thefollowing equation: % Solids = (F − T) ÷ (I − T) * 100. Where: F = Finalweight of remaining coating and aluminum dish in grams, I = Initialweight of coating and aluminum dish in grams, T = Tare weight of thealuminum dish in grams, and 100 is the conversion factor to percentage.

TABLE 2 COATING COMPOSITION Ingredient 6 7 8 9 Pre-mix 1 95.9 (48.4)95.9 (48.4) 95.9 (48.4) 95.9 (48.4) Pre-mix 2 86.3 (58.0) 57.4 (38.6)57.4 (38.6) 71.9 (48.3) Silylated — 20.1 (19.4) — — Compound A Silylated— — 23.1 (19.4) 11.5 (9.7) Compound B Polybutyl 0.50 (0.30) 0.50 (0.30)0.50 (0.30) 0.50 (0.30) acrylatetm¹ Blocked acid 2.50 (1.00) 2.50 (1.00)2.50 (1.00) 2.50 (1.00) catalyst² Reduction Information Methyl 3.51 — —1.80 n-amyl ketone Butyl 3.51 — — 1.80 Cellosolve ® acetate³ Butyl 0.78— — 0.40 Carbitol ® acetate⁴ Spray 28 29 28 28 viscosity⁵ (sec) Paint 7373 74 74 temperature (° F.) 230° F. 53 58 57 56 (110° C.) % Solids⁶ ¹Aflow control agent having a Mw of 6700 and a Mn of 2600 made in xyleneat 60% solids available from DuPont. ²Dodecyl benzene sulfonic acidsolution, blocked with diisopropanol amine to 91% total neutralization,40 percent acid solids in ethanol. ³2-Butoxyethyl acetate solvent iscommercially available from Union Carbide Corp. ⁴2-(2-Butoxyethoxy)ethyl acetate is commercially available from Union Carbide Corp.⁵Viscosity measured in seconds with a #4 FORD efflux cup at ambienttemperature. ⁶% Solids of a coating is determined by taking a specificquantity of the coating and adding it into a tarred aluminum dish andrecording the coating weight. Three milliliters of xylene is added intothe aluminum dish to dissolve and/or disperse the coating. The coatingis then heated in an oven for sixty minutes at 230° F. (110° C.). Afterremoval from the oven, the aluminum dish is cooled, re-weighed, and thenon-volatile content (weight percent solids) is calculated using thefollowing equation: % solids = (F − T) ÷ (I − T)* 100. Where: F = Finalweight of remaining coating and aluminum dish in grams, I = Initialweight of coating and aluminum dish in grams, T = Tare weight of thealuminum dish in grams, and 100 is the conversion factor to percentage.

TABLE 3 COATING COMPOSITION Ingredient 10 11 12 Pre-mix 4 97.6 (64.8)97.6 (64.8) 97.6 (64.8) Pre-mix 2 — 33.6 (22.6) 16.8 (11.3) SilylatedCompound B 53.8 (45.2) 26.9 (22.6) 40.4 (33.9) Polybutyl acrylate¹ 0.67(0.40) 0.67 (0.40) 0.67 (0.40) Acid catalyst² 1.43 (1.00) 1.43 (1.00)1.43 (1.00) Reduction Information Methyl n-amyl 0.62 2.7 1.48 ketoneButyl 1.25 5.4 2.95 Cellosolve ® acetate³ Butyl Carbitol ® 0.21 0.900.49 acetate⁴ Spray viscosity⁵ (sec) 27 28 28 Paint temperature (° F.)74 74 74 230° F. (110° C.) 66 63 63 % Solids⁶ ¹A flow control agenthaving a Mw of 6700 and a Mn of 2600 made in xylene at 60% solidsavailable from DuPont. ²Dodecyl benzene sulfonic acid solution (70%solids in isopropanol) available from Chemcentral. ³2-Butoxyethylacetate solvent is commercially available from Union Carbide Corp.⁴2-(2-Butoxyethoxy) ethyl acetate is commercially available from UnionCarbide Corp. ⁵Viscosity measured in seconds with a #4 FORD efflux cupat ambient temperature. ⁶% Solids of a coating is determined by taking aspecific quantity of the coating and adding it into a tarred aluminumdish and recording the coating weight. Three milliliters of xylene isadded into the aluminum dish to dissolve and/or disperse the coating.The coating is then heated in an oven for sixty minutes at 230° F. (110°C.). After removal from the oven, the aluminum dish is cooled,re-weighed, and the non-volatile content (weight percent solids) iscalculated using the following equation: % Solids = (F − T) ÷ (I − T)*100. Where: F = Final weight of remaining coating and aluminum dish ingrams, I = Initial weight of coating and aluminum dish in grams, T =Tare weight of the aluminum dish in grams, and 100 is the conversionfactor to percentage.

TESTING

Coating Compositions 1–12 were spray applied over a pigmented basecoatto form color-plus-clear composite coatings over primed electrocoatedsteel panels. The panels used were cold rolled steel panels (size 4inches×12 inches (10.16 cm by 30.48 cm)) coated with ED5100 electrocoatand PCV70100M primer, both available from PPG Industries, Inc. The testpanels are available as APR30471 from ACT Laboratories, Inc. ofHillsdale, Mich.

Coating Compositions 1–5 were tested over two different basecoats,namely: HWB9517, a black pigmented water-based acrylic/melamine basecoatcommercially available from PPG Industries, Inc, and a black pigmentedwater-based acrylic/melamine basecoat (Basecoat X), the formulation forwhich is given below. Coating Compositions 6–12 were evaluated overBasecoat X.

Basecoat X Ingredient Parts by weight (grams) Solid weights (grams)Hexyl Cellosolve ®¹ 20.0 — 2-Butoxyethanol 20.0 — Phosphatized Epoxy²1.00 0.60 TINUVIN 1130³ 3.00 3.00 CYMEL 1156⁴ 25.0 25.0 VISCOLAM 330⁵3.33 1.00 Deionized Water 100.0 — Odorless Mineral 20.0 — Spirits⁶BYK-032⁷ 3.90 2.00 Acrylic Latex⁸ 125.3 51.5 SETALUX 6802 61.2 15.0AQ-24⁹ Amine¹⁰ 3.00 — Black tint paste¹¹ 47.6 11.5 ¹Ethylene glycolmonohexyl ether solvent commercially available from Union Carbide Corp.²Phosphatized epoxy prepared from EPON 828, a polyglycidyl ether ofBisphenol A available from Shell Oil and Chemical Co.; reacted withphosphoric acid in an 83:17 weight ratio. ³Substituted hydroxyphenylbenzotriazole available from Ciba Specialty Chemicals Corp. ⁴Methylatedmelamine formaldehyde resin available from Cytec Industries, Inc.⁵Acrylic thickener available from Lamberti in Italy. ⁶Solvent availablefrom Shell Chemical Co. ⁷Defoamer available from Byk Chemie. ⁸TheAcrylic Latex was prepared as follows: The polyester was prepared in afour-neck round bottom flask equipped with a thermometer, mechanicalstirrer, condenser, dry nitrogen sparge, and a heating mantle. Thefollowing ingredients were used: 1103.0 g isostearic acid  800.0 gpentaerythritol  470.0 g crotonic acid  688.0 g phthalic anhydride   6.1g dibutyltin oxide   6.1 g triphenyl phosphite 1170.0 g butyl acrylate  4.0 g lonol (butylated hydroxytoluene) The first six ingredients werestirred in the flask at 210° C. until 245 ml of distillate was collectedand the acid value dropped to 46. The material was cooled to 77° C. andthe last two ingredients were stirred in. The final product was aviscous yellow liquid with a hydroxyl value of 54.0, a Gardner-Holdtviscosity of Z+, a weight average molecular weight of 45,600, and anon-volatile content of 70.2%. A pre-emulsion was prepared by stirringtogether the following ingredients:  286.0 g polyester of example III 664.0 g butyl acrylate  30.0 g ethylene glycol dimethacrylate  20.0 gacrylic acid  46.4 g dodecylbenzenesulfonic acid (70% in isopropanol) 14.3 g dimethylethanolamine 1000.0 g water The reaction was carried outusing the same procedure and materials as in Latex Example I. Thereaction exothermed from 23° C. to 80° C. The final pH of the latex was6.1, the nonvolatile content was 42.4%, the particle size was 105 nm,and the Brookfield viscosity was 14 cps (spindle #1, 50 rpm). ⁹Rheologycontrol agent available from Akzo Nobel. ¹⁰Dimethylethanolamine, 50%Aqueous, available from Union Carbide Corp. ¹¹Black pigment availablefrom Cabot Corp. as MONARCH BLACK 1300 dispersed in an acrylic grindvehicle (35% butyl acrylate, 30% styrene, 18% butyl methacrylate, 8.5%2-hydroethyl acrylate, 8.5% acrylic acid) at a total pigment to binderration (P/B) of 0.35.

Two coats of basecoat were automated spray applied to the electrocoatedand primed steel panels at ambient temperature (70° F. (21° C.)). Noflash was permitted between the application of the two basecoat layers.The total dry film thickness of the basecoat was 0.5 to 0.7 mils (13 to18 micrometers). After the second basecoat application, a 1 to 10 minuteair flash at ambient temperature was given before force flashing thebasecoated panels. For panels basecoated with HWB9517, the force flashwas ten minutes at 200° F. (93° C.). The panels basecoated with BasecoatX were forced flashed for five minutes at 200° F. (93° C.). CoatingCompositions 1–12 were each automated spray applied to a basecoatedpanel at ambient temperature in two coats with a ninety second ambientflash between applications. The total dry film thickness of theclearcoat was 1.5 to 1.8 mils (38 to 46 micrometers). All coatings wereallowed to air flash at ambient temperature for ten minutes. Panelsprepared from each coating were baked for thirty minutes at 285° F.(141° C.) to fully cure the coating(s). The panels were baked in ahorizontal position.

To test recoat adhesion, each panel was coated with another layer ofbasecoat and clearcoat or clearcoat only, as specified below. Examples1–5 were recoated with HWB9517 or Basecoat X and Coating Compositions1–5, depending on the respective original panel. Examples 6–12 wererecoated with Basecoat X and Coating Compositions 6–12, depending on therespective original panel. For example, Coating Composition 5 overHWB9517 original (prepared above) was recoated with HWB9517 and CoatingComposition 5 clearcoat. Half of an original panel from Examples 1–12was basecoated and clearcoated and the other half of the panel wasclearcoated only. To recoat the panels, the bottom halves of theoriginal panels were covered with aluminum foil and then the respectivebasecoats were automated spray applied as described above. The foil wasremoved, resulting in an original panel with the upper half coated inbasecoat and the bottom half still with only the original coatinglayers. The panels were force flashed as described above. The respectiveclearcoat was then automated spray applied to the entire panel asdescribed above. The resulting panels were half coated inbasecoat/clearcoat from the original spray application and another layerof basecoat/clearcoat from the recoat spray application (B/C//B/C). Theother half of the resulting panel was coated in basecoat/clearcoat fromthe original spray application and another layer of clearcoat from therecoat spray application (B/C//C).

Properties for the coatings are reported below in Table 4 for Examples101–5 over HWB9517 basecoat and Table 5 for Examples 1–12 over BasecoatX.

TABLE 4 % 20° Gloss Retained after scratch testing² Initial Postweathering³ Knoop Recoat Adhesion⁵ Example # 20° Gloss¹ Initial 286Hours 618 Hours Hardness⁴ B/C//B/C B/C//C 1 85 79 82 84 10.3 0 0 2 85 1825 58 4.0 0 0 3 84 1 5 8 <2.0 0   4+ 4 84 6 14 20 <2.0 0 4 5 83 1 13 18<2.0 0 4

TABLE 5 % 20° Gloss Retained after scratch testing² Initial Postweathering³ Knoop Recoat Adhesion⁵ Example # 20° Gloss¹ Initial 286Hours 618 Hours Hardness⁴ B/C//B/C B/C//C 1 87 91 84 71 12.7 0 0 2 87 7880 64 9.9   4+ 0 3 87 27 20 20 13.8 5   4+ 4 88 81 28 26 11.5   4+ 4 588 71 53 44 9.9   4+ 4 6 87 91 — — 10.9 1 0 7 86 67 — — 7.7   4+ 0 8 8767 — — 8.1   4+ 0 9 85 91 — — 10.4 4 0 10 87 49 — — 5.8   4+   4+ 11 8567 — — 6.7 4   1+ 12 87 59 — — 6.6   4+   3+ ¹20° gloss was measuredwith a Statistical Novo-Gloss 20° gloss meter, available from Paul N.Gardner Company, Inc. ²Coated panels were subjected to scratch testingby linearly scratching the coated surface with a weighted abrasive paperfor ten double rubs using an Atlas AATCC Scratch Tester, Model CM-5,available from Atlas Electrical Devices Company of Chicago, Illinois.The abrasive paper used was 3M 281Q WETORDRY ™ PRODUCTION ™ 9 micronpolishing paper sheets, which are commercially available from 3M Companyof St. Paul, Minnesota. Panels were then rinsed with tap water andcarefully patted dry with a paper towel. The 20° gloss was measured(using the same gloss meter as that used for the initial 20° gloss) onthe scratched area of each test panel. Using the lowest 20° glossreading from the scratched area, the scratch results are reported as thepercent of the initial gloss retained after scratch testing using thefollowing calculation: 100% * scratched gloss ÷ initial gloss. Highervalues for percent of gloss retained are desirable. ³Post-weatheringscratch resistance (retained scratch resistance) was measured using thescratch test method described above after the unscratched test panelswere subjected to simulated weathering by exposure to UVA-340 bulbs in aQUV Accelerated Weathering Tester available through Q Panel LabProducts. Testing was as follows: a cycle of 70° C. for 8 hours exposureto UVA followed by a condensation cycle at 50° C. for 4 hours with noUVA (total test time is reported in the table). Using the lowest 20°gloss reading from the scratched area, the scratch results are reportedas the percent of the initial gloss retained after post-weatheringscratch testing using the following calculation: 100% post-weatheringscratched gloss ÷ initial gloss. Higher values for percent of glossretained are desirable. ⁴Knoop hardness is a hardness measurementderived from the size of an indentation in the coating made using theTukon Microhardness Instrument. The Tukon Microhardness Instrument makesan indentation in a cured coating by applying a 25 gram load to thesurface with a diamond tip. The size of the indentation is measuredusing a microscope. That indentation size is then converted to the KnoopHardness measurement. The Tukon Microhardness Instrument used was theTukon Microhardness Tester Model 300 manafactured by Wilson Instruments,Division of Instron Corporation. ⁵Recoat adhesion tests the adhesion ofthe recoat layer (either basecoat/clearcoat or clearcoat only) to theoriginal layers (steel/electrodeposition/primer/basecoat/clearcoat) tosimulate repair coatings. An eleven-blade claw with 1.5 mm spaced teeth(blade and handle/blade holder are available from Paul N. GardnerCompany, Inc.) was used to scribe the cured coating. Two sets of scribeswere made by scribing the second set on top of and perpendicular to thefirst set. Detached flakes and ribbons of coating were wiped off thepanel and strapping tape (3M #898 available from 3M Company) wassmoothed firmly over the crosshatch marking. Within 90 seconds ofapplication, the tape was removed in one continuous motion directedtoward the tester and as parallel to the panel as possible. The scribedarea was inspected and rated for removal of the recoat layer to thesubstrate according to the following scale: 5 = The edges of the cutsare completely smooth and none of the lattice squares is detached. 4 =Small flakes of coating are detached at intersections: Less than fivepercent of the area is affected. 3 = Small flakes of the coating aredetached along edges and at intersections of cuts. The area affected isfive to fifteen percent of the lattice. 2 = The coating has flaked alongthe edges and on parts of the squares. The area affected is fifteen tothirty-five percent of the lattice. 1 = The coating has flaked along theedges of cuts in large ribbons and whole squares have detached. The areaaffected is thirty-five to sixty-five percent of the lattice. 0 =Flaking and detachment worse than rating 1. Over sixty-five percent ofthe lattice is affected.

EXAMPLE 2

Silylated compounds for use in the coating compositions disclosed belowwere prepared as follows:

Silylated Compound C

This example illustrates the preparation of a silylated compound that isa half acid ester of methyl hexahydrophthalic anhydride andtrimethylolpropane with residual carboxyl groups reacted with propyleneoxide.

A reaction vessel equipped with stirrer, thermocouple, temperaturecontrol, pumps and fitted with valved ports was charged with 4436.7grams methyl hexahydrophthalic anhydride (commercially available fromMilliken Chemical), 1202.9 grams trimethylolpropane (commerciallyavailable from Bayer USA), 14.4 grams of triphenyl phosphine(commercially available from Aldrich®), 12.1 grams of triisooctylphosphite (commercially available from GE Specialty Chemicals), and800.0 grams of n-butyl acetate (commercially available from UnionCarbide Chemicals and Plastics Co., Inc.).

The reaction was heated to 115° C. and held 4 hours. 1533.4 grams ofpropylene oxide (commercially available from Fisher Scientific Company)was charged to the reactor over 1 hour. The reaction was held 3 to 5hours until the acid value was less than 4.87 mg KOH/gram. Residualpropylene oxide was removed by vacuum distilling at 60 to 80 mm Hg at100 to 115° C. The resultant product had a total solids content of94.8%.

This product was silylated by the following procedure: 2700.0 grams ofthe previously described material were charged to a reaction flaskequipped with an overhead stirrer, nitrogen inlet, thermocouple,addition funnel, and condenser. The temperature was increased to 90° C.under nitrogen blanket, at which time 762.39 grams hexamethyldisilazane(commercially available from Aldrich®) were added drop-wise over a threehour period. The reaction was allowed to continue one additional hour,at which time a nitrogen sparge was introduced. The reaction wasconsidered complete when the size of the IR peak corresponding to thehydroxyl moiety was negligible. Resin solids content was 95.8%.

Silylated Compound D

This example illustrates the preparation of a silylated compound that isa half acid ester of methyl hexahydrophthalic anhydride andtrimethylolpropane with residual carboxyl groups reacted with propyleneoxide.

A reaction vessel equipped with stirrer, thermocouple, temperaturecontrol, pumps and fitted with valved ports was charged with 4436.7grams methyl hexahydrophthalic anhydride, 1202.9 gramstrimethylolpropane, 14.4 grams of triphenyl phosphine, 12.1 grams oftriisooctyl phosphite, and 800.0 grams of n-butyl acetate. The reactionwas heated to 115° C. and held 4 hours. 1533.4 grams of propylene oxidewas charged to the reactor over 1 hour. The reaction was held 3 to 5hours until the acid value was less than 4.87 mg KOH/gram. Residualpropylene oxide was removed by vacuum distilling at 60 to 80 mm Hg at100 to 115° C. The resultant product had a total solids content of98.1%.

This product was divided into three batches and silylated by thefollowing procedure: 1830.0 grams of the previously described materialwere charged to a reaction flask equipped with an overhead stirrer,nitrogen inlet, thermocouple, addition funnel, and condenser. Thetemperature was increased to 90° C. under nitrogen blanket, at whichtime 535.36 grams hexamethyldisilazane were added drop-wise over a 2.5hour period. The reaction was allowed to continue one additional hour,at which time the temperature was increased to 110° C. The reaction wasconsidered complete when the size of the IR peak corresponding to thehydroxyl moiety was negligible. The product was cooled to roomtemperature and diluted with t-butyl acetate. The three batches wereblended together. Resin solids were 95%.

Silylated Compound E

This example illustrates the preparation of a silylated compound that isa half acid ester of hexahydrophthalic anhydride and trimethylolpropanewith residual carboxyl groups reacted with propylene oxide.

A reaction vessel equipped with stirrer, thermocouple, temperaturecontrol, pumps and fitted with valved ports was charged with 2014.4grams hexahydrophthalic anhydride, 595.6 grams trimethylolpropane, 7.1grams of triphenyl phosphine, 6.0 grams of triisooctyl phosphite, and376.8 grams of n-butyl acetate. The reaction was heated to 115° C. andheld 4 hours. 758.8 grams of propylene oxide was charged over a one hourperiod. The reaction was held three to five hours until the acid valuewas less than 5.0 mg KOH/gram. Residual propylene oxide was removed byvacuum distilling at 60 to 80 mm Hg at 100 to 115° C. The resultantproduct had a total solids content of 89.0%.

This product was silylated by the following procedure: 400.0 grams ofthe previously described material were charged to a reaction flaskequipped with an overhead stirrer, nitrogen inlet, thermocouple,addition funnel, and condenser. The temperature was increased to 90° C.under nitrogen blanket, at which time 111.8, grams hexamethyldisilazanewere added drop-wise over a 40 minute period. After one additional hour,the temperature was increased to 110° C. and held for one hour. Thereaction was considered complete when the size of the IR peakcorresponding to the hydroxyl moiety was negligible. The resin solidscontent was 91.2% solid.

Silylated Compound F

This example illustrates the preparation of a silylated compound that isa half acid ester of methyl hexahydrophthalic anhydride andpentaerythritol with residual carboxyl groups reacted with propyleneoxide.

A reaction vessel equipped with stirrer, thermocouple, temperaturecontrol, pumps and fit with valved ports was charged with 2472.4 gramsmethyl hexahydrophthalic anhydride, 510.6 grams pentaerythritol(commercially available from Hoechst-Celanese), 7.7 grams of triphenylphosphine (Aldrich®), 6.5 grams of triisooctyl phosphite, and 426.3grams of n-butyl acetate. The reaction was heated to 115° C. and held 4hours. Then 854.1 grams of propylene oxide was charged over 1 hour. Thereaction was held 3 to 5 hours until acid value was less than 8.76 mgKOH/gram. Residual propylene oxide was removed by vacuum distilling at60 to 80 mm Hg at 100 to 115° C. The resultant product had a totalsolids content of 95.8%.

The product was silylated by the following procedure: 700.0 grams of thepreviously described material were charged to a reaction flask equippedwith an overhead stirrer, nitrogen inlet, thermocouple, addition funnel,and condenser. The temperature was increased to 90° C. under blanket, atwhich time 207.84 grams hexamethyldisilazane were added drop-wise over a30 minute period. The reaction was allowed to continue one additionalhour. At this time the temperature was increased to 110° C. for onehour. The product was cooled to room temperature and thinned with 50grams t-butyl acetate. The resin solids were 93.5%.

Silylated Compound G

This example illustrates the preparation of a silylated compound that isa half acid ester of methyl hexahydrophthalic anhydride andtrimethylolpropane with residual carboxyl groups reacted with propyleneoxide.

A reaction vessel equipped with stirrer, thermocouple, temperaturecontrol, pumps and fitted with valved ports was charged with 1977.9grams methyl hexahydrophthalic anhydride, 536.0 gramstrimethylolpropane, 6.4 grams of triphenyl phosphine, 5.4 grams oftriisooctyl phosphite, and 168.9 grams of t-butyl acetate. The reactionwas heated to 115° C. and held 4 hours. Charged to the reactor was 683.3grams of propylene oxide over 1 hour. The reaction was held 3 to 5 hoursuntil the acid value reached 1.71 mg KOH/gram. Residual propylene oxidewas removed by vacuum distilling at 60 to 80 mm Hg at 75° C. Theresultant product had a total solids content of 94.2%.

This product was 80% silylated (80% of the hydroxyl groups wereconverted to silyl ether groups) by the following procedure: 500.0 gramsof the previously described material were charged to a reaction flaskequipped with an overhead stirrer, nitrogen inlet, thermocouple,addition funnel, and condenser. The temperature was increased to 90° C.under nitrogen blanket, at which time 112.27 grams hexamethyldisilazanewere added drop-wise over a 45 minute period. The reaction was allowedto continue one additional hour, at which time the temperature wasincreased to 110° C. and allowed to continue for one hour. The materialwas thinned with 50.0 grams t-butyl acetate. Resin solids were 91%.

Compound H

This example illustrates the preparation of a compound that is a halfacid ester of methyl hexahydrophthalic anhydride and trimethylolpropanewith residual carboxyl groups reacted with propylene oxide.

A reaction vessel equipped with stirrer, thermocouple, temperaturecontrol, pumps and fitted with valved ports was charged with 2029.6grams methyl hexahydrophthalic anhydride, 550.0 gramstrimethylolpropane, 6.6 grams of triphenyl phosphine, 5.59 grams oftriisooctyl phosphite, and 205.73 grams of t-butyl acetate. The reactionwas heated to 115° C. and held 4 hours. Charged to the reactor was769.89 grams of propylene oxide over 1 hour. The reaction was held 3 to5 hours until the acid value was less than 5.00 mg KOH/gram. Residualpropylene oxide was removed by vacuum distilling at 60 to 80 mm Hg at70° C. The resultant product was diluted with t-butyl acetate to a totalsolids of 80.8%.

Silylated Compound I

This example illustrates the preparation of a silylated compound that isa half acid ester of methyl hexahydrophthalic anhydride andtrimethylolpropane with the residual carboxyl groups reacted withethylene oxide.

A reaction vessel equipped with stirrer, thermocouple, temperaturecontrol, pumps, and fit with valved ports was charged with 1977.0 gramsof methyl hexahydrophthalic anhydride, 536.0 grams trimethylolpropane,6.4 grams triphenyl phosphine, 5.4 grams triisooctyl phosphite, and152.1 grams of t-butyl acetate. The reaction was heated to 115° C. andheld for 4 hours. 518.0 grams of ethylene oxide (commercially availablefrom Scott Specialty Gases) was added over 1 hour. The reaction was heldat 115° C. for 3 to 5 hours until acid value was 12.0 mg KOH/gram. Anyresidual ethylene oxide was removed by vacuum distilling at 60 to 80 mmHg at 115° C. The resulting product had a total solids content of 98.8%.

This product was silylated by the following procedure: 500.0 grams ofthe previously described material were charged to a reaction flaskequipped with an overhead stirrer, nitrogen inlet, thermocouple,addition funnel, and condenser. The temperature was increased to 90° C.under nitrogen blanket, at which time 155.1 grams hexamethyldisilazanewere added drop-wise over a 1 hour, 5 minute period. After one hour, thereaction temperature was increased to 110° C. and held for an additionalhour. The reaction was considered complete when the size of the IR peakcorresponding to the hydroxyl moiety was negligible. The reaction wascooled to room temperature and diluted with 50 grams t-butyl acetate.The resin solids were 91.0%.

Silylated Compound J

This example illustrates the preparation of a silylated compound that isa half acid ester of methyl hexahydrophthalic anhydride andtrimethylolpropane with the residual carboxyl groups reacted withCARDURA E (glycidyl ester of a branched C10 saturated carboxylic acid,available from Shell Chemical Co.).

A triol was prepared from the following ingredients:

Chemical Amount in grams trimethylol propane 268.4 n-butyl acetate 240.6triphenyl phosphite 5.4 methyl hexahydrophthalic anhydride 987.8triphenyl phosphite 2.7 CARDURA E¹ 1470.0 ¹Glycidyl ester of a branchedC10 saturated carboxylic acid, available from Shell Chemical Co.

The first three ingredients were charged to a suitable reactor equippedwith an stirrer, thermocouple and N₂ inlet and heated to 115° C. under anitrogen blanket. Methyl hexahydrophthalic anhydride was added to thereactor over a period of 2 hours while maintaining a temperature between115 and 120° C. After the addition was complete, the reaction mixturewas held at 115° C. until the anhydride was judged to be gone byinfrared spectroscopy. Triphenyl phosphite was added to the reactor;CARDURA E was then added to the reactor over 4 hours while maintaining atemperature between 115 and 120° C. The reaction mixture was held at116° C. to a measured acid value of 6.8. The resulting resin had aviscosity (Gardner-Holt bubble tube) of Z8, a measured solids (110° C.,1 hr) of 89.8 percent, a number average molecular weight of 1195, aweight average molecular weight of 1295, and a polydispersity of 1.07 asdetermined by gel permeation chromatography vs. a polystyrene standard.

The triol was silylated according to the following procedure:

Chemical Amount in grams Triol 643.5 hexamethyldisilazane (Aldrich ®)209.3 xylene 120.9

The triol was charged to a suitable reactor equipped with a stirrer,thermocouple and N₂ inlet and heated to 110° C. under an N₂ blanket. Thesolvent was stripped out of the reaction mixture under reduced pressure.The reaction was then cooled to 60° C. and hexamethyldisilazane wasadded to the reaction mixture drop-wise. A foamy reaction ensued; thereaction mixture was cooled with an ice bath to 15° C. and the additionof hexamethyldisilazane continued until complete. The reaction was helduntil the hydroxyl groups were judged to be gone by infraredspectroscopy. Excess hexamethyldisilazane was stripped from the reactionmixture under reduced pressure, starting initially at 18° C. and endingat a maximum temperature of 90° C. The reaction mixture was then allowedto cool to ambient temperature and thinned with xylene. The resultingresin had a viscosity (Gardner-Holt bubble tube) of G, a number averagemolecular weight of 1488, a weight average molecular weight of 1568, anda polydispersity of 1.05 as determined by gel permeation chromatographyvs. a polystyrene standard. Resin solids were 85.0%.

Silylated Compound K

This example illustrates the preparation a silylated acrylic.

Into a reaction flask equipped with an overhead stirrer, nitrogen inlet,thermocouple, addition funnel, and condenser was placed 1407.0 grams ofhydroxyl functional acrylic consisting of 40% hydroxypropyl acrylate/20%styrene/18.5% butyl methacrylate/19% butyl acrylate/0.5% methylmethacrylate/2% acrylic acid and having a solid equivalent weight of325. The temperature was increased to 115° C. and as much residualsolvent as possible was vacuum stripped. The temperature was thenreduced to 90° C. at which time 58.0 grams hexamethyldisilazane wereadded drop-wise over a 20 minute period. The reaction was allowed tocontinue one additional hour. The reaction was considered complete whenthe size of the IR peak corresponding to the hydroxyl moiety wasnegligible. The resin solids were 90%.

Compound L A hydroxyl functional branched polyester was prepared fromthe following ingredients: Chemical Amount in grams Trimethylolpropane321.6 Methyl hexahydrophthalic anhydride 1189.4 ESTERDIOL 204¹ 1473.7Butyl stannoic acid 4.5 Triphenyl phosphite 3.0¹2,2-dimethyl-3-hydroxypropyl-2,2-dimethyl-3-hydroxypropanoate,available from Union Carbide Chemicals and Plastics Co., Inc.Trimethylolpropane, methyl hexahydrophthalic anhydride, ESTERDIOL 204,butyl stannoic acid, and triphenyl phosphite were charged to a suitablereactor equipped with a stirrer, thermocouple and nitrogen inlet andheated to 80° C. under an N₂ blanket. At 80° C. the nitrogen blanket wasconverted to a nitrogen sparge; and the reaction mixture was held atthis temperature and sparged with nitrogen for 20 minutes. Thetemperature of the reaction mixture was then raised to 210° C. withremoval of 130 ml of H₂O from the reactor and held at this temperatureto a measured acid value of 4.3. The resinous product was cooled to<1000° C. and reduced with n-butyl acetate. The resulting resin has aviscosity (Gardner-Holt bubble tube) of T-U, a measured solids (110° C.,1 hr) of 73.0%, a number average molecular weight of 1185, a weightaverage molecular weight of 2942, and a polydispersity of 2.50 asdetermined by gel permeation chromatography vs. a polystyrene standard.

Silylated Compound M

The hydroxyl functional branched polyester was silylated by thefollowing procedure: 2000.0 grams of the hydroxyl functional branchedpolyester were charged to a reaction flask equipped with an overheadstirrer, nitrogen inlet, thermocouple, addition funnel, and condenser.The temperature was increased to 90° C. under a nitrogen blanket, atwhich time 282.3 grams of hexamethyldisilazane were added drop-wise overa 1 hr 15 minute period. The reaction was held an additional two hours.The reaction was considered complete when the IR peak due to thehydroxyl moiety was negligible. Resin solids were 74.1%.

Silylated Compound N

This example illustrates the preparation and silylation of an adduct ofmethyl hexahydrophthalic anhydride and trimethylolpropane withtheoretically one hydroxyl group reacted with DESMODUR W(4,4′-methylenebis(cyclohexyl isocyanate), available from Bayer USA)with the residual carboxyl groups reacted with propylene oxide.

A low molecular weight urethane with terminal acid functionality wasprepared according to the following procedure:

Chemical Amount in grams n-butyl acetate 1125.0 trimethylolpropane 603.1methyl hexahydrophthalic anhydride 1512.0 dibutyltin dilaurate 1.3DESMODUR W¹ 571.8 ¹4,4-methylenebis(cyclohexyl isocyanate), availablefrom Bayer USA.Butyl acetate and trimethylolpropane were charged to a suitable reactorequipped with a stirrer, thermocouple and N₂ inlet and heated to 110° C.under an N₂ blanket. Methyl hexahydrophthalic anhydride was added to thereactor over a period of 2 hours while maintaining a temperature between110 and 120° C. After the addition was complete, the reaction mixturewas held at 110° C. until the anhydride was judged to be gone byinfrared spectroscopy. The reaction mixture was cooled to 70° C.;dibutyltin dilaurate (commercially available from Air Products andChemicals, Inc.) was then added to the reactor. DESMODUR W was added tothe reaction mixture at a rate such that the reaction temperature wascontrolled between 70 and 80° C. The reaction was held at 70° C. untilinfrared spectroscopy showed that all the isocyanate was consumed. Theproduct was then cooled and poured out. The resulting resin had aviscosity (Gardner-Holt bubble tube) of >Z5, a measured solids (110° C.,1 hour) of 74.6%, a number average molecular weight of 598, a weightaverage molecular weight of 1358, and a polydispersity of 2.30 asdetermined by gel permeation chromatography versus a polystyrenestandard.

A reaction vessel equipped with stirrer, thermocouple, temperaturecontrol, pumps and fitted with valved ports was charged with 3000 gramsof urethane with terminal acid functionality as described above, 3.0grams of triphenyl phosphine, 3.4 grams of triisooctyl phosphite. Thismixture was heated to 115° C. Charged to the reaction was 319.2 grams ofpropylene oxide over 1 hour. Hold 3 to 5 hour until acid value is lessthan 13.7 mg KOH/gram. Residual propylene oxide was removed by vacuumdistilling at 60 to 80 mm Hg at 85° C. The resultant product had aweight average molecular weight of 2200 Daltons, and solids of 86.2%.

This product was silylated by the following procedure: 1784.0 grams ofthe previously described material were charged to a reaction flaskequipped with an overhead stirrer, nitrogen inlet, thermocouple,addition funnel, and condenser. The temperature was increased to 90° C.under nitrogen blanket, at which time 345.1 grams hexamethyldisilazanewere added drop-wise over a one hour, 45 minute period. The reaction wasallowed to continue for one hour, at which time a nitrogen sparge wasintroduced. After one additional hour, the temperature was increased to110° C. After 30 minutes, the temperature was decreased to 100° C. and30.0 g additional hexamethyldisilazane were added over a 10 minuteperiod. The temperature was increased to 110° C. and held for two hours.The reaction was cooled and reduced with 250 grams t-butyl acetate. Theproduct had a final hydroxyl value of 14.8 mg KOH/gram and resin solidsof 78.8%.

Silylated Compound O

This example illustrates the preparation of a silylated that is a halfacid ester of methyl hexahydrophthalic anhydride and2-ethyl-1,3-hexanediol with residual carboxyl groups reacted withpropylene oxide.

A reaction vessel equipped with stirrer, thermocouple, temperaturecontrol, pumps and fit with valved ports is charged with 1977.9 gramsmethyl hexahydrophthalic anhydride, 877.3 grams 2-ethyl-1,3-hexanediol(commercially available from Hüls, Inc.), 6.4 grams of triphenylphosphine, 5.4 grams of triisooctyl phosphite, and 394.4 grams ofn-butyl acetate. Heat to 115° C. and hold 4 hours or until anhydride isinfinite by IR spectroscopy. Charge 683.3 grams of propylene oxide over1 hour. Hold 3 to 5 hours until acid value is less than 5.6 mg KOH/gram.Remove residual propylene oxide by vacuum distilling at 60 to 80 mm Hgat 100 to 115° C. The resultant product had a total solids content of94.4% and a weight average molecular weight of 650 Daltons.

This product was silylated by the following procedure: 1500.0 grams ofthe previously described material were charged to a reaction flaskequipped with an overhead stirrer, nitrogen inlet, thermocouple,addition funnel, and condenser the temperature was increased to 90° C.under nitrogen blanket, at which time 381.1 grams hexamethyldisilazanewere added drop-wise over a 1 hour, 25 minute period. The reaction washeld at 90° C. for an additional hour. The reaction was consideredcomplete when the size of the IR peak corresponding to the hydroxylmoiety was negligible. The resin solids were 95.4%.

Silylated Compound P

This example illustrates the preparation of a silylated that is a halfacid ester of methyl hexahydrophthalic anhydride and2-ethyl-1,3-hexanediol with residual carboxyl groups reacted with1,4-butanediol diglycidyl ether.

A low molecular weight polyol was prepared according to the followingprocedure:

Chemical Amount in grams 2-ethyl-1,3-hexanediol 346.8 methylhexahydrophthalic anhydride 399.0 1,4-butanediol diglycidyl ether 240.2triphenyl phosphine 4.9 n-butyl acetate 166.32-ethyl-1,3-hexanediol was charged to a suitable reactor equipped with astirrer, thermocouple and nitrogen inlet and heated to 110° C. under anN₂ blanket. Methyl hexahydrophthalic anhydride was added to the reactionmixture over a period of 96 minutes; the reaction was then held untilthe anhydride was judged to be gone by infrared spectroscopy. A mixtureof 1,4-butanediol diglycidyl ether and triphenyl phosphine was thenadded to the reaction mixture over a period of 26 minutes; the reactionwas then held until the acid value stalled (34.2). A measurement of theepoxy equivalent weight at this point indicated that most of the epoxygroups had been consumed (epoxy equivalent weight of 28879). Theresinous product was reduced with butyl acetate. The resulting resin hasa viscosity (Gardner-Holt bubble tube) of Z1, a measured solids (110°C., 1 hr) of 78.0 percent, a number average molecular weight of 787, aweight average molecular weight of 1479, and a polydispersity of 1.90 asdetermined by gel permeation chromatography vs. a polystyrene standard.

The above product was silylated by the following procedure: 150.0 gramsof the previously described material were charged to a reaction flaskequipped with an overhead stirrer, nitrogen inlet, thermocouple,addition funnel, and condenser. The temperature was increased to 90° C.under a nitrogen blanket, at which time 27.0 grams ofhexamethyldisilazane were added drop-wise over a 15 minute period. Thereaction was held an additional two hours at which time a nitrogensparge was introduced. An additional 3 grams of hexamethyldisilazanewere added and the reaction was held two hours. The reaction wasconsidered complete when the IR peak due to the hydroxyl moiety wassignificantly reduced. Resin solids were 80.5%.

Silylated Compound Q

A low molecular weight polyol was prepared according to the followingprocedure:

Chemical Amount in grams dimethyl azelate 260.0 1,4-butanediol 216.0zinc acetate dihydrate 5.7The above three ingredients were charged to a reactor equipped with amechanical stirrer, Dean-Stark trap, dry ice condenser, thermocouple,and nitrogen sparge line and heated to 130° C. under ambient atmosphericconditions. The temperature was raised in 5 degree increments to 170° C.over 3 hours. After the three hours were complete, the temperature ofthe system was raised to 200° C. Nitrogen gas was slowly bubbled throughthe sparge tube to aid removal of methanol from the flask. The reactionwas held for 1 additional hour, by which point 75.5 grams methanol (77grams theory) had been collected. The reaction mixture was then cooledand poured. The resulting material after cooling to ambient temperaturewas a soft, white waxy solid with a number average molecular weight of864, a weight average molecular weight of 1251, and a polydispersity of1.4 as determined by gel permeation chromatography vs. a polystyrenestandard.

Into a round bottom flask equipped with an overhead stirrer, nitrogeninlet, nitrogen outlet with drying tube, thermocouple, addition funnel,and condenser was placed 362.1 grams of the above material. Thetemperature was increased to 90° C. at which time 59.0 grams ofhexamethyldisilazane was added over 40 minutes. 25 grams of solvent wereadded and the reaction temperature was increased to reflux for 2 hours.29.5 grams of hexamethyldisilazane were added and the reactiontemperature was increased to 115° C. for 2 hours. The temperature wasthen increased to 125° C. for 1.5 hours. The reaction was cooled to roomtemperature. The final hydroxyl value was 205.9 and resin solids wereapproximately 91%.

Composition Pre-Mixtures

The following pre-mixtures of selected components of the coatingcompositions discussed below were prepared by sequentially mixing eachof the components with agitation.

Pre Mix A: Ingredient Parts by weight (grams) Solid weights (grams)SOLVESSO 100¹ 5.0 — Butyl Cellosolve ® 5.0 — acetate² Methyl n-amylketone 3.0 — TINUVIN ® 928³ 3.0 3.0 Polybutyl acrylate⁴ 0.7 0.4TINUVIN ® 292⁵ 0.4 0.4 TINUVIN ® 123⁶ 0.6 0.6 Multiflow⁷ 0.6 0.3 DDBSA⁸1.4 1.0 ¹Aromatic solvent, 100 type, available from Exxon ChemicalsAmerica. ²2-Butoxyethyl acetate solvent is commercially available fromUnion Carbide Corp.³2-(2H-Benzotriazol-2yl)-6-(1-methyl-1-phenylethyl)-4-(1,1,3,3-tetramethylbutyl)phenolUV absorber available from Ciba Specialty Chemicals Corp. ⁴A flowcontrol agent having a Mw of 6700 and a Mn of 2600 made in xylene at 60%solids available from DuPont. ⁵Sterically hindered amine lightstabilizer commercially available from Ciba Specialty Chemicals Corp.⁶Bis-(1-octyloxy-2,2,6,6-tetramethyl-4-piperidinyl) sebacate hinderedaminoether light stabilizer available from Ciba Specialty ChemicalsCorp. ⁷50% solution of MODAFLOW ®, available from Solutia Inc., suppliedin xylene. MODAFLOW ® is a polymer made of 75% by weight 2-ethyl hexylacrylate, 25% by weight ethyl acrylate with a number average molecularweight of 7934. ⁸Dodecyl benzene sulfonic acid solution, 70% solid inisopropanol, available from Chemcentral. Pre Mix B: Ingredient Parts byweight (grams) Solid weights (grams) CYMEL ® 1130¹ 75.0 75.0 RESIMENE ®741² 28.4 25.0 ¹Methylated and butylated melamine-formaldehyde resinavailable from Cytec Industries, Inc. ²Methylated melamine-formaldehyderesin available from Solutia Inc.

The pre-mixtures of ingredients from Pre-Mixes A and B were used inCoating Compositions 13–32. The components for forming CoatingCompositions 13–32 are listed below in Tables 6–10. The amounts listedare the total parts by weight in grams and the amount within parenthesisare percentages by weight based on weight of resin solids. Eachcomponent was mixed sequentially with agitation.

TABLE 6 COATING COMPOSITION NO. Ingredient 13 14 15 16 17 Pre-mix A 19.7(5.7)  19.7 (5.7)  19.7 (5.7)  19.7 (5.7)  19.7 (5.7)  Pre-mix B 41.2(39.8) 41.2 (39.8) 41.2 (39.8) 42.2 (40.8) 42.0 (40.6) SilylatedCompound C 62.8 (60.2) — 56.4 (54.1) — — Silylated Compound D — 63.4(60.2) — — — Silylated Compound E — — — 64.9 (59.2) — Silylated CompoundF — — — — 63.5 (59.4) Black tint paste¹ — — 17.5 (6.1) — — ReductionInformation SOLVESSO 100² 4.6 4.6 3.0 4.4 5.9 Butyl Cellosolve ® acetate4.6 4.6 3.0 4.4 5.9 Spray viscosity⁴ (sec) 56 55 45 52 47 Painttemperature (° F.) 74 73 73 72 73 230° F. (110° C.) % Solids⁵ 70 61 6568 67 ¹Black pigment available from Cabot Corp. as MONARCH BLACK 1300dispersed in a 56.0:44.0 blend of acrylic grind vehicle (29.5% styrene,19.7% 2-ethylhexyl acrylate, 19.2% n-butyl methacrylate, 17.7% methylmethacrylate, 9.8% hydroxyethyl acrylate, 1.9% methacrylic acid, 1.3%t-dodecyl mercaptan, 0.5% glacial acetic acid, 0.4% propylene imine) andpolyester (65% trimethyl pentanediol, 35% hexahydrophthalic anhydride)at a total pigment to binder ratio P?B) of 0.18.x ²Aromatic solvent, 100type, available from Exxon Chemicals America. ³2-Butoxyethyl acetatesolvent is commercially available from Union Carbide Corp. ⁴Viscositymeasured as described in Example 1 above. ⁵% Solids of a coating isdetermined as described in Example 1 above.

TABLE 7 COATING COMPOSITION NO. Ingredient 18 19 20 21 Pre-mix A 19.7(5.7)  19.7 (5.7)  19.7 (5.7)  19.7 (5.7)  Pre-mix B 43.7 (42.3) 43.9(42.5) 42.2 (40.8) 31.7 (30.7) Silylated — 33.5 (32.1) — — Compound CSilylated 63.4 (57.7) — — — Compound G Compound H — 31.8 (25.4) — —Silylated — — 65.1 (59.2) — Compound I Silylated — — — 81.5 (69.3)Compound J Reduction Information SOLVESSO 4.9 5.8 4.2 0.0 100¹ Butyl 4.95.8 4.2 0.0 Cellosolve ® acetate² Spray 57 54 54 47 viscosity³ (sec)Paint 73 73. 74 73 temperature (° F.) 230° F. 69 69 68 71 (110° C.) %Solids⁴ ¹See Table 6 above. ²See Table 6 above. ³See Table 6 above. ⁴SeeTable 6 above.

TABLE 8 Ingredient 22 23 24 25 Pre-mix A 19.7 (5.7)  19.7 (5.7)  19.7(5.7)  19.7 (5.7)  Pre-mix B 39.3 (38.0) 41.8 (40.4) 37.0 (35.8) 39.2(37.9) Silylated 29.9 (28.7) 31.9 (30.6) 28.3 (27.1) 29.9 (28.7)Compound C Silylated 37.0 (33.3) — — — Compound K Acrylic¹ — 41.4 (29.0)— — Compound L — — — 45.8 (33.4) Silylated — — 50.1 (37.1) — Compound MReduction Information SOLVESSO 6.4 8.4 2.8 4.0 100² Butyl 6.4 8.4 2.84.0 Cellosolve ® acetate³ Spray 54 56 48 59 viscosity⁴ (sec) Paint 74 7373 73 temperature (° F.) 230° F. 67 63 66 67 (110° C.) % Solids⁵¹Hydroxyl functional acrylic consisting of 40% hydroxypropylacrylate/20% styrene/18.5% butyl methacrylate/19% butyl acrylate/0.5%methyl methacrylate/2% acrylic acid and having a solid equivalent weightof 325. ²See Table 6 above. ³See Table 6 above. ⁴See Table 6 above. ⁵SeeTable 6 above.

TABLE 9 Ingredient 26 27 28 Pre-mix A 19.7 (5.7)  19.7 (5.7)  19.7(5.7)  Pre-mix B 20.6 (19.9) — — Silylated Compound C 69.3 (66.4) 52.4(50.2) 66.6 (63.8) CYLINK ® 2000¹ 26.6 (13.7) — — VESTANAT B1358A² —79.0 (49.8) — DESMODUR N-3390³ — — 40.2 (36.2) DBTDL⁴ 0.5 0.05 ReductionInformation SOLVESSO 100⁵ 0.6 7.7 1.0 Butyl Cellosolve ® acetate⁶ 0.67.7 1.0 Spray viscosity⁷ (sec) 56 58 60 Paint temperature (° F.) 73 7372 230° F. (110° C.) % Solids⁸ 67 58 75 ¹Tris (alkylcarbamoyl) triazineavailable from CYTEC Industries, Inc. The alkyl substituent was mixedmethyl and butyl. ²Methyl ethyl ketoxime blocked isophorone diisocyanateisocyanurate available from Hüls, Inc. ³Isocyanurate of hexamethylenediisocyanate, available from Bayer USA. ⁴Dibutyl tin dilaurate availableas METACURE ® T-12 from Air Products & Chemicals, Inc. ⁵See Table 6above. ⁶See Table 6 above. ⁷See Table 6 above. ⁸See Table 6 above.

TABLE 10 Ingredient 29 30 31 32 Pre-mix A 19.7 (5.7)  19.7 (5.7)  19.7(5.7)  19.7 (5.7)  Pre-mix B 35.7 (34.5) 39.2 (37.9) 32.3 (31.2) 34.7(33.6) Silylated 83.1 (65.5) — — — Compound N Silylated — 65.1 (62.1) —— Compound O Silylated — — 77.8 (62.6) — Compound P Silylated — — — 73.0(66.4) Compound Q Reduction Information SOLVESSO 7.5 2.5 8.3 0.0 100¹Butyl 7.5 2.5 8.3 0.0 Cellosolve ® acetate² Spray 60 56 60 35 viscosity³(sec) Paint 72 71 72 73 temperature (° F.) 230° F. 61 71 63 76 (110° C.)% Solids⁴ ¹See Table 6 above. ²See Table 6 above. ³See Table 6 above.⁴See Table 6 above.

TESTING

Coating Compositions 13 and 16–32 were spray applied over a pigmentedbasecoat to form color-plus-clear composite coatings over primedelectrocoated steel panels. Coating Composition 14 was spray applied toa pigmented basecoat to form a color-plus-clear composite coating overelectrocoated only steel panels. Coating Composition 15 was sprayeddirectly over primed electrocoated steel panels to form a pigmentedmonocoat.

The panels used for Coating Compositions 13 and 16–17, 20–21 and 24–32were cold rolled steel panels (4″×12″ (10.16 cm×30.48 cm)) coated withED5100 electrocoat available from PPG Industries, Inc. Test panels areand PCV70100M primer, both available from PPG Industries, Inc. The testpanels are available as APR30471 from ACT Laboratories, Inc. ofHillsdale, Mich. The panels used for Coating Composition 14 were coldrolled steel panels (size 4 inches×12 inches (10.16 cm by 30.48 cm))coated with ED5000 electrocoat, available as APR22986 from ACTLaboratories, Inc. of Hillsdale, Mich. The panels for Examples 15, 18,19, 22, and 23 were cold rolled steel (size 4 inches×12 inches (10.16 cmby 30.48 cm)) coated with ED5250 electrocoat and FCP6744 primer, bothavailable from PPG Industries, Inc. The ED5250 test panels are availablefrom ACT Laboratories, Inc.

The basecoat for Examples 13, and 16–32 is available from PPGIndustries, Inc. as DCT6373, a black pigmented solvent-basedacrylic/melamine basecoat. The basecoat for Example 14 is DWBH9939, ablack pigmented water-based acrylic/melamine basecoat, available fromPPG Industries, Inc. Basecoats were spray applied in two coats to eitherelectrocoated only steel or electrocoated and primed steel panels asspecified above at ambient temperature (70° F. (21° C.)). No flash wasgiven between the two basecoat applications. For DCT6373 basecoat(Examples 13 and 16–32) the dry film thickness was 0.6 to 0.8 mils (15to 20 micrometers). The dry film thickness for DWBH9939 (Example 14)basecoat was 0.55 to 0.7 mils (14 to 18 micrometers). After the secondbasecoat application, an un-timed air flash at ambient temperature wasgiven before force flashing the basecoated panels. For examples 13 and16–32, the basecoated panels were forced flashed for five minutes at200° F. (93° C.). The basecoated panels for Example 14 were forceflashed ten minutes at 200° F. (93° C.).

The clear coating compositions of Examples 13, 14, and 16–32 were eachapplied to a basecoated panel at ambient temperature in two coats with aninety second ambient flash between applications. Dry film thicknesstarget was 1.5 to 2.0 mils (38 to 51 micrometers). Example 15 wasapplied to electrocoated and primed steel panels in two coats with aninety second ambient flash between applications. Example 15 had a 1.6to 1.8 mils (41 to 46 micrometers) dry film thickness. All coatings,except Examples 14 and 26, were allowed to air flash at ambienttemperature for ten minutes. Example 14 was allowed to air flash forseven minutes at ambient temperature. Example 26 was allowed to airflash at ambient temperature for ten minutes and then it was forceflashed for ten minutes at 140° F. (60° C.). Panels prepared from eachcoating were baked for twenty-five minutes at 285° F. (141° C.) to fullycure the coating(s). The panels were baked in a horizontal position.Properties for the coatings are reported below in Table 11.

TABLE 11 Xylene Spot/ Example 20° Knoop Pencil Crosshatch # Gloss¹Hardness² Hardness³ Adhesion⁴ 13 89 14.4 2B 5 14 90 14.9 2B 5 15 89 12.73B 5 16 91 16.4 2B 5 17 90 15.2 2B 5 18 90 14.3 3B 5 19 89 14.3 3B 5 2090 13.8 2B 5 21 85 <2.0 <6B   5 22 89 14.4 3B 5 23 91 12.6 3B 5 24 8815.3 2B 5 25 89 15.8 2B 5 26 88 16.2  B 5 27 83 17.3  B 5 28 83 15.6 2B5 29 88 17.4 2B 5 30 89 13.8 2B 5 31 87 12.9 2B 5 32 57 <2.0 <6B   5¹See Example 1 above. ²Knoop hardness is a hardness measurement derivedfrom the size of an indentation in the coating made using the TukonMicrohardness Instrument. The Tukon Microhardness Instrument makes anindentation in a cured coating by applying a 25 gram load to the surfacewith a diamond tip. The size of the indentation is measured using amicroscope. That indentation size is then converted to the KnoopHardness measurement. The Tukon Microhardness Instrument used was theTukon Microhardness Tester Model 300 manufactured by Wilson Instruments,Division of Instron Corporation. ³Xylene spot/pencil hardness testmeasures the gouge hardness of a cured coating after an organic solventhas been placed on the coating for a specified amount of time. In thistest the solvent used was xylene and it was left on the panel for threeminutes. After the spot of xylene was wiped off, a pencil hardness testwas run to determine the gouge hardness of the coating. Gouge hardnessis defined as the hardest pencil (from a range of a soft 6B to a hard 6Hpencil or drawing lead) that will leave the film uncut. ⁴Crosshatchadhesion tests the adhesion of the clearcoat to thesteel/electrodeposition/primer/basecoat combined substrate. Aneleven-blade claw with 1.5 mm spaced teeth (blade and handle/bladeholder are available from Paul N. Gardner Company, Inc.) was used toscribe the cured coating. Two sets of scribes were made by scribing thesecond set on top of and perpendicular to the first set. Detached flakesand ribbons of coating were wiped off the panel and strapping tape (3M#898 available from Minnesota, Mining and Manufacturing Co. -3M) wassmoothed firmly over the crosshatch marking. Withing 90 seconds ofapplication, the tape was removed in one continuous motion dirctedtoward the tester and as parallel to the panel as possible. The scribedarea was inspected and rated for removal of clearcoat to the substrateaccording to the following scale: 5 = The edges of the cuts arecompletely smooth and none of the lattice squares is detached. 4 = Smallflakes of coating are detached at intersections. Less than five percentof the area is affected. 3 = Small flakes of the coating are detachedalong edges and at intersections of cuts. The area affected is five tofifteen percent of the lattice. 2 = The coating has flaked along theedges and on parts of the squares. The area affected is fifteen tothirty-five percent of the lattice. 1 = The coating has flaked along theedges of cuts in large ribbons and whole squares have detached. The areaaffected is thirty-five to sixty-five percent of the lattice. 0 =Flaking and detachment worse than rating 1. Over sixty-five percent ofthe lattice is affected.

The compositions of the present invention can provide numerousadvantages in coating applications, including, but not limited to, theability to formulate high solids, low VOC coating compositions, goodinitial and retained mar resistance, good appearance properties such asgloss and distinctiveness of image, good recoat adhesion and physicalproperties such as good flexibility and weatherability.

It will be appreciated by those skilled in the art that changes could bemade to the embodiments described above without departing from the broadinventive concept thereof. It is understood, therefore, that thisinvention is not limited to the particular embodiments disclosed, but itis intended to cover modifications which are within the spirit and scopeof the invention, as defined by the appended claims.

1. A coating composition formed from components comprising: (a) at leastone hydroxyl functional non-vinyl material comprising at least onealcoholic hydroxyl group blocked with a hydrolyzable silyl group; and(b) at least one curing agent reactive with the alcoholic hydroxyl groupof the at least one hydroxyl functional non-vinyl material (a).
 2. Acoated substrate comprising a substrate and a composition according toclaim 1 deposited over at least a portion of the substrate.
 3. A methodfor forming a cured coating on a substrate comprising applying over atleast a portion of the substrate a coating composition according toclaim
 1. 4. A method according to claim 3, wherein the substrate is anautomotive substrate.
 5. A coated automobile substrate comprising anautomobile substrate and a composition according to claim 1 depositedover at least a portion of the automobile substrate.
 6. A coatedautomobile substrate according to claim 5, wherein the automobilesubstrate is a bumper.
 7. A coated automobile substrate according toclaim 5, wherein the automobile substrate is a hood.
 8. A coatedautomobile substrate according to claim 5, wherein the automobilesubstrate is a door.
 9. A coated automobile substrate according to claim5, wherein the automobile substrate is a fender.
 10. A multi-componentcomposite coating composition comprising a basecoat deposited from apigmented coating composition, and a composition according to claim 1applied over at least a portion of the basecoat.
 11. A multi-componentcomposite according to claim 10, wherein the composition is a topcoat.12. A multi-component composite according to claim 10, wherein thecomposition is transparent after curing.
 13. A method for making amulti-component composite comprising: (a) applying a pigmentedcomposition to a substrate to form a basecoat; (b) applying a topcoatingcomposition according to claim 1 over at least a portion of thebasecoat; and (c) curing the topcoating composition to form a curedcoating.
 14. A coating composition formed from components comprising:(a) at least one hydroxyl functional material comprising at least onehydroxyl group blocked with a hydrolyzable silyl group, the hydroxylfunctional material having a polydispersity of less than 2; and (b) atleast one curing agent reactive with the at least one hydroxyl group of(a).
 15. A coating composition according to claim 14, wherein thehydroxyl functional material having a polydispersity of less than 1.5.16. A coating composition according to claim 15, wherein the hydroxylfunctional material having a polydispersity of less than 1.2.
 17. Acoating composition formed from components comprising: (a) at least onehydroxyl functional material comprising at least one hydroxyl groupblocked with a hydrolyzable silyl group, the hydroxyl functionalmaterial having less than 5 hydroxyl functional groups; and (b) at leastone curing agent reactive with the at least one hydroxyl group of (a).18. A coating composition formed from components comprising: (a) atleast one hydroxyl functional material comprising at least one hydroxylgroup blocked with a hydrolyzable silyl group; and (b) at least 10weight percent on a basis of total resin solids of the components whichform the coating composition of at least one curing agent reactive withthe at least one hydroxyl group of (a).
 19. A coating composition formedfrom components comprising: (a) at least one carbamate functionalmaterial comprising at least one carbamate group blocked with ahydrolyzable silyl group; and (b) at least one curing agent reactivewith the at least one carbamate group of (a).
 20. A coating compositionformed from components comprising: (a) at least one carboxyl functionalnon-vinyl material comprising at least one carboxyl group blocked with ahydrolyzable silyl group; and (b) at least one curing agent reactivewith the at least one carboxyl group of (a).